
Class 



Book. 



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CopigM? 



COEXRIGHT DEPOSIT. 



FOUNDRY 

MOULDING MACHINES 

AND 

PATTERN EQUIPMENT 



This ADVANCE EDITION is an abridgment of a 
complete book bearing this title, which is to appear in 
July, 1919. It is requested that published reviews be 
withheld, and circulation limited, remembering that 
this is a special "author's edition" for presentation only. 



FOUNDRY 

MOULDING MACHINES 

AND 

PATTERN EQUIPMENT 



A TREATISE 

SHOWING THE PROGRESS 

MADE BY THE FOUNDRIES USING 

MACHINE MOULDING 

METHODS 



AUTHOR'S EDITION 
ILLUSTRATED 



By 

E. S. gARMAN 

Mechanical Engineer 

Mem. A S M E 

Mem. C E S 



NEW YORK 

THE NORMAN W. HENLEY PUBLISHING CO. 

2 West 45th Street 
1919 






Copyrighted, 1919 

By 

E. S. CARMAN 

All Rights Reserved 



P 



THE GARDNER PRINTING CO., CLEVELAND 



©CI.A512606 

MAK 10 1919 



INTRODUCTION 

TOURING the past years marvelous advances have been made 
in the amount of production obtained from the daily efforts 
of man, This is true not only in the industrial establishments, 
but is true in practically all walks of life, and especially does this 
fact stand forth in our home life, transportation, trucking, farm- 
ing, merchandising, and in the industrial arts ; it is evident in 
the steel mills, machine shop, pattern shop, and in some few 
foundries, especially those foundries engaged in the manufacture 
of automobile castings. The increased production that is obtain- 
able in these and many other lines of daily activities, has been 
brought about by the utilization and application of scientific 
knowledge, engineering principles and mechanical appliances. 

This is a mechanical age. The hard, drudging, physical 
effort is being taken out of labor. Labor is now, in nearly all 
instances, being performed by the pulling of a lever, or the press- 
ing of a button. The farm life is easy; plowing is performed 
by power, the wheelbarrow has become a truck, the Japanese 
jinrikisha an automobile, the hammer and chisel is replaced by 
a lathe and planer ; but to the foundry in general these contrasts 
will not apply, as the moulding, in some plants, is still being 
performed in the same manner as it has been for centuries past. 
The mould is still made in the old-style wood flask, hand-rammed 
by the same old laborious method, and very little accomplished 
at the day's close. Instead of being fresh and vigorous, the man 
is all tired out, the production small, and in many cases the cast- 
ings defective. 

A new day is upon us. It is here ; we cannot change it ; 
regardless of our individual attitude, it is here to stay ; we can- 
not even delay its workings ; we must launch out into the current 
of modern activities or the current will strand us upon the reef. 
Our individual effort will be judged by the amount of work pro- 
duced. There will be no place for the man who is willing to work 



through a hard, long, day of drudgery in order to perform his 
daily work, but instead he who can produce as his day's work 
maximum production with a minimum of effort will be the one 
who stands the highest. 

The manufacturer today is not desirous of obtaining a max- 
imum production by means of exacting hard hours of labor, but 
instead, in the great majority of industries, the maximum pro- 
duction is obtained by mechanical means with minimum labor. 

The foundry has been one of the last to adopt mechanical 
means of saving hard, drudging, labor, and the very fact of its 
being late in starting is perhaps the reason for the rapid devel- 
opment that has been made. 

A further progress will have been made when more atten- 
tion has been given by engineers to detail casting design in order 
to meet the foundry's requirements as to moulding methods, and 
by the manufacturer when ordering or having made the patterns 
that are to be used by the foundry. 

It is with a view to stimulating co-operation between 
foundrymen, manufacturers, and engineers that this book is 
written. Their working together will be the means of producing 
the world's ever increasing casting supply in an easier and better 
way. The author, believing that pictures are of great value in 
the presentation of ideas, has endeavored, by a very liberal use 
of engravings, to illustrate the method of mounting patterns, and 
the making of moulds by machine power. 




A Study in Contrasts 





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Then 




A Study in Contrasts 




Today (Why?) 



Today 



CONTENTS 



CHAPTER PAGE 

I. The Theory of Jolt-Ramming. . . .' 1-7 

Imperfections of hand rammed moulds 1 

Jolt-ramming — how accomplished and results 1 

Correct principle of jolt-ramming — with diagrams 4 

Cushioning of the blow and its effect 5 

Plan and sections of a well designed mould 7 

II. The Roll-Over Jolt-Moulding Machine for Large Moulds 8-20 

Description and operation of the machine 9 

TTIiiQtrrftimn f Tunnel segment castings 12 

„!Sln J Railway castings 14 

and Production Shipbu f lding casti 15 

Comparisons [ u*^ ^ ^^ l7 

III. The Roll-Over Jolt-Moulding Machine for Medium Size 

Moulds 22-46 

Description and operation of the machine 23 

]' Automobile castings 26 

T11 , .. i Tractor castings 29 

Illustrations Aeroplane cas £ 30 

and Production < A ^ , , , ° ,. 91 

Comparisons b rm £? ed *T ?• Stmgs S 

F | Machine tool castings 32 

[ Shipbuilding industry 34 

Views of foundry floors 40 

IV. The Roll-Over Jolt-Moulding Machine for Small Moulds 48-61 

Description and operation of the machine 49 

Illustrations f Automobile castings 53 

and Production ] Armored truck castings 55 

Comparisons ( High pressure steam trap casting 57 

Shipbuilding industry 58 

Views of foundry floors 60 

V. The Jolt-Moulding Machine in Aluminum and Brass 

Foundries 62-68 

Describing and illustrating the making of Liberty motor castings. 64 

VI. Plain Jolt-Moulding Machines for Various Size Moulds 70-87 

Description and operation 71 

Illustrations [Generator castings 78 

SSSSSo. K'^r. — . :;::;:;:::;:;;;;; j? 

Comparisons | Miscellaneous ^ astings 82 

Views of foundry floors 87 



CONTENTS 



CHAPTER PAGE 

VII. Air-Operated Squeezer Moulding Machines 88-96 

Combination jolt squeezer 89 

Sand straddler squeezer 91 

Description 92 

Operation 92 

Views of foundry floors 93 

VIII. Pattern Equipment 

Important features of construction 97-115 

Metal patterns and pattern-plates 98 

Wood patterns and pattern-plates 100 

Comparison of machine and floor patterns 102 

Match-plates and vibrator frames 104 

Using match-plates and vibrator frame 110 

Stripping-plate patterns with stools 112 

IX. Machine Moulded Cores 117-122 

Bench production of small cores 117 

Gauging and inspection of dry-sand cores 117 

Assembling of complicated cores — assembling and setting jigs.. .119 

Green sand cores 120 

Tunnel segment cores 122 

X. Flask Equipment 123-129 

Importance in machine moulding 123 

Objectionable features of wood flasks 123 

Snap flasks 124 

Cast-iron flasks and bottom plates 125 

Cut flasks 127 

Rolled steel flasks 128 

XL Foundations for Jolt-Ramming Moulding Machines 131-143 

Theory of foundation impact 132 

Varying nature of soils 134 

Construction 134 

Accessibility to the machine 138 

Illustrations of installations 139 

A proposed ideal foundry design 142 



FOUNDRY 

MOULDING MACHINES 

AND 

PATTERN EQUIPMENT 



CHAPTER I 
Theory of Jolt-Ramming 

Every foundryman is familiar with the skill required in pro- 
ducing- a hand-rammed mould for the pouring of a casting. The 
mould, to be poured successfully, must be rammed in such a man- 
ner as will prevent swells, scabs, blowholes, etc. When such a 
performance is undertaken by hand-ramming, trouble is expe- 
rienced in securing a mould with a surface upon which the metal 
is to lay, that. is of uniform hardness and without the adjacent 
hard and soft spots, which, when the metal is poured, cause the 
gases to flow to the soft spots instead of entering the surface of 
the sand without flowing. 

It is obvious that the moulder with his small tamp could not, 
without exceptional skill, produce a surface of even strength and 
texture and without initial strains in the body of the sand. The 
pouring of the hot metal against the sand releases the strains 
caused by uneven ramming by taking away the binding elements, 
allowing the sand to flow until it becomes of uniform hardness, 
sufficient to withstand the pressure of the metal. This movement 
of the sand is the cause of the rough, uneven surfaces that are 
usually seen on the castings produced by hand-rammed moulds. 

In contrast with the above described hand method, the iron 
will lie properly and the gases enter the sand uniformly in the 
mould that is produced by jolt-ramming on a machine. 

Jolt-ramming is accomplished by the lifting of the table, pat- 
tern, flask and sand a short distance and then allowing them to 
drop and contact with an anvil which stops and reverses the 
table, pattern and flask, but allows the sand to continue onward 



2 Foundry Moulding Machines and Pattern Equipment 

in its descending course, producing a slipping action between the 
flask and sand, also producing a pressure on the sand lying near- 
est the pattern and pattern-plate. By a repeated number of ma- 
chine blows the sand is caused to flow to the bottom of the mould 
and pack into the flask corners and around the pattern in a uni- 




Fig. 1 



Fig. 2 





Fig. 3 

form manner ; the jolting action of the machine causes the grains 
of sand to flow in the direction of least resistance, and therefore 
the mould is packed in an even and uniform manner and without 
setting up strains between the different sections. 

The development of the jolt-ramming method of moulding 
has produced a machine that will jolt-ram a mould complete in 
from 5 to 30 seconds of time, operating with a strpke of 1" to 
2" in length, and at a rate of 150 to 250 strokes per minute. It 



Theory of Jolt-Ramming 



is well to point out the fact that after the mould has been prop- 
erly rammed either by hand or the machine, it is many times 
spoiled or damaged by the moulder attempting to draw the pat- 
tern from the sand by hand; distortion of the mould takes place 
by rapping the pattern ; this also destroys the life of the pattern, 




Fig. 4 




Fig. 5 

which of necessity must be made of a light and fragile material. 
Since the saving in time effected by means of jolt-ramming 
is perhaps not more than 20 to> 25 per cent of the whole, it is 
advisable that more time be saved by having a machine that not 
only jolts but also rolls over the mould, and draws the pattern 
from the sand. These operations are being performed by ma- 
chine power in from 10 to 30 seconds of time, producing a mould 
that has not been distorted or broken, and leaving the patterns 
undamaged by rapping. 



4 Foundry Moulding Machines and Pattern Equipment 

It has been found that to produce a machine that will jolt- 
ram a mould in the manner described in the preceding paragraphs 
there should be no pause in the upward action of the stroke, but, 
on the contrary, the upward action of the stroke should start rap- 
idly and at the instant of table contact with the anvil, in order to 
prevent the moving parts from coming to rest at the end of the 
slight rebound stroke, due to impact only. If this impact rebound 
is allowed to expend itself before the table again starts on its 
upward stroke by means of the power, the pressure on the sand 
is then released and instead of pressure, the sand itself rebounds 
and retards or destroys the packing action. Machines that do not 
make use of this pressure require a longer time in which to pack 
the sand, and indicator cards taken from such a machine would 




Fig. 6 

be as shown in Figures 1 and 2, in which the extreme width of 
Figure 1 represents the pressure required to lift the table with 
equipment, and the extreme width of the shaded portion of Fig- 
ure 2 represents the pressure at the time of contact. Since the 
indicator diagram Figure 2 shows that the pressure in the 
cylinder at the time of contact is only one-half of the amount 
required to lift the load, it is obvious that the moving parts will 
rebound and that, without sufficient pressure in the cylinder, the 
parts will, when the force of the rebound is spent, settle back 
again until sufficient air is admitted to the cylinder to obtain the 
pressure required to again lift the load. 

The indicator cards shown in Figures 3-4 are taken from a 
machine having a balanced piston type valve, so constructed as to 



Theory of Jolt-Ramming 



close the exhaust after the air from the previous stroke has been 
exhausted, also admitting- line air to the cylinder before the falling 
load has contacted with the anvil, resulting in the moving parts 
being rapidly reversed after contacting, and the sand pressure in 
the mould maintained during part of the upward stroke. 

The width of the shaded portion of Figure 3 represents the 
air pressure required to lift the load ; the width of the shaded 
portion of Figure 4 represents the pressure developed by the 
downward movement of the piston acting upon the air, at atmos- 
pheric pressure in the cylinder, after the exhaust is closed, and 




Fig. 7 



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Fig. 8 

also upon the admitted compressed air ; the resulting pressure is 
from 10 to 20% higher than the pressure required to lift the load, 
and takes place at a point in the stroke just before contact is 
made and, therefore, does not appreciably lessen the speed of the 
falling parts but does, however, cushion the blow so that the 
force of the blow is not transmitted to the base and foundation, 
the contact being necessary to cause the reversal of the moving 
parts, which is sufficient to properly ram the sand; nor is there 
the heavy strain set up in the falling parts as would otherwise 
be the case if the whole load were allowed to fall with the full 
force of gravity. The action obtained in the moving parts is 



6 Foundry Moulding Machines and Pattern Equipment 

rapid, and at the time of contact with the anvil they are resiliently 
reversed in their direction of travel, while the sand, being loose, 
continues its pressure downward without rebounding and be- 
coming again loose in the flask. 

Figures 6, 7 and 8 show a manner in which machines are 
tested to determine the quality of the packing action, also uni- 
formity of stroke and valve action. 

The diagram shown in Figure 6 represents a reading made 
by the testing of a jolt-moulding machine to ascertain the rela- 
tion of the falling parts and their load, to the relation of the 
valve action. This style of test is also used in ascertaining the 
effect of compression in retarding the inertia of the falling parts. 

The diagram appearing in Figure 7 represents the packing 
qualities of the machine and is also used to determine the uni- 
formity of stroke. 

Figure 8 discloses an irregularity of action and indicates 
existing trouble, which, when overcome, should produce a dia- 
gram similar to that shown in Figure 7. 

Testing diagrams, such as referred to above, are a decided 
benefit in producing duplicate machines. Experience has shown 
that the stroke which produces good packing results with one 
grade of sand does not always produce equal results when using 
a different grade, and, likewise, any decided variation in pattern 
and flask equipment requires an alteration of stroke to produce 
the same results in the same length of time. 



Theory of Jolt-Ramming 




BOTTOM PLATE 



RAM UP RUNNER CORE 



Fig. 9. Plan and Sections of a Well Designed Mould, explaining the terms 
used in the following Chapters. 



Foundry Moulding Machines and Pattern Equipment 




Fig. 10. A Large Roll-Over Jolt-Moulding Machine, with Foundations cut 
away to show the construction underneath the foundry floor. 



CHAPTER II 

Roll-Over Jolt-Moulding Machine for 
Large Moulds 

In this chapter is shown a varied line of large castings 
that can be advantageously made on a Roll-Over Jolt-Moulding 
Machine, ranging in capacity from 3,000 pounds to 12,000 
pounds, with a table length of 72 to 150 inches. 

The machine shown on the opposite page has a table length 
of 106 inches and a lifting capacity of 7,000 pounds. 

The operations performed are jolting, rolling over the flask, 
lowering the mould on a receiving table, and drawing the pattern. 
These operations are accomplished by the use of compressed air 
at a pressure of 80 pounds per square inch. 

The pattern draw on a machine of this type should be posi- 
tive and extremely accurate. In some instances manufacturers 
require a micrometer test from each machine before shipment; 
the variation being held to less than .0005" per inch of travel. 
Lubrication is of the utmost importance, and the jolting 
valve and piston should be equipped with a forced-feed oiling 
system or some other means of supplying sufficient lubrication. 
Wherever possible, all working parts should be encased to pre- 
vent the entrance of sand, grit, etc. 

It must be understood that the machine method of produc- 
ing moulds does not eliminate any of the various operations that 
are ordinarily necessary for the producing of the same moulds 
by hand or floor moulding. The moulding machine, therefore, 
can only be considered a means of reducing the amount of time 
and labor formerly necessary to perform the same series of oper- 
ations. For the purpose of illustration, the attention of the 
reader is directed to the views on page 12 and likewise to the 
production table on the opposite page. From the figures in the 
production table, it becomes evident that nearly 50% of the 
time occupied in making the drag, without the aid of a moulding 
machine, was used in the ramming operation. 



10 Foundry Moulding Machines and Pattern Equipment 

The operations required for the producing of a drag- or 
cope mould on the machine shown on page 12 and the means 
by which those operations are performed are as follows : 

It is assumed that the pattern has been secured to the table 
of the machine and the flask placed in its proper position and 
clamped to the pattern-plate. Sand is riddled into the flask to a 
depth sufficient to cover the face side of the pattern ; the flask 
is then filled with sand directly from the sand supply ; the sand 
conveying system shown in Figure 11 provides an easy and eco- 
nomical means of performing this operation (altho not a 
necessity and rarely used except in Specialty Foundries). After 
the flask is filled, the operator in charge of the machine opens a 
valve, admitting compressed air to the jolt cylinder thru the 
jolt valve; the jolt piston rises and falls, carrying with it the 
table on which the pattern and flask are mounted ; the mould 
is jolted or jarred at the rate of 100 to 160 blows per minute. 
(20 to 80 blows are used per mould, the number of blows neces- 
sary being dependent on the depth of the flask and density de- 
sired.) After being jolted, the flask is "butted off" and then 
"struck off" and the bottom plate securely fastened to the flask; 
iron "C" clamps (which are tightened by means of wedges driven 
between the clamp and the bottom plate) have been found to be 
excellent for this purpose. The ramming is now complete and 
the mould ready for rolling over. 

The operator then opens an air valve, admitting compressed 
air to the roll-over cyclinder, which raises the table on which 
the pattern is mounted and, in its upward travel, rolls over the 
mould. The table is securely locked in this position and a car 
known as a "run-out car," provided with devices that level the 
mould, is run into the space underneath the mould ; the mould 
is then lowered upon the car by allowing the air in the cylinder 
to escape; when lowered, the leveling devices are adjusted to any 
unevenness of the bottom plate, after which the clamps, securing 
the flask to the pattern, are removed. 

The vibrators, which are devices similar to pneumatic ham- 
mers, and are secured to the table upon which the pattern is 
mounted, are set in operation and impart a vibratory action to 



Roll-Over Jolt-Moulding Machine for Large Mouids 11 

the pattern serving- to loosen the pattern in the sand. This action 
does not perceptibly enlarge the impression of the pattern in the 
mould. With the vibrators in operation, the valve admitting the 
air to the roll-over or draw cylinder is again opened and the 
pattern drawn from the mould, the speed with which the pat- 
tern is drawn being perfectly controlled by the operator. The 
mould, now resting on the car, is next run out from beneath 
the pattern ; the roll-over table, on which the pattern is mounted, 
is unlocked and tilted slightly, after which the compressed air 
is released from the roll-over cylinder, and the roll-over table, 
with the pattern, returns to the jolting position, ready for another 
empty flask for making the next mould. 

In order to more clearly set forth the advantages to be 
gained by the use of the Jolt-Moulding methods, a tabulation has 
been made showing the machine best adapted for producing the 
cope and the drag, also the production that can be obtained by 
the use of the two different styles of Jolt-Moulding Machines. 
The tabulation shows clearly that the greatest production is ac- 
complished by the machine that produces mechanically all the 
operations required to make the mould. 



Foundry Moulding Machines and Pattern Equipment 















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Fig. 11. Tunnel Segment Mould — Lower 
or Drag Half— Made on a Roll-Over Jolt 
Machine. In the view shown above, the 
machine is rolling over the mould after it 
has been jolted and bottom board clamped. 

After the rolling-over operation is com- 
pleted, the mould is lowered on the run-out 
car, shown in the rear, clamps removed 
and pattern drawn from the mould. 




The lower view shows the completed lower half or drag mould before 
the core is set. 

In the background can be seen the enormous production obtained, a 
performance which extended over a period of two years, resulting in a 
large saving over the hand-rammed method. 



Roll-Over Jolt-Moulding Machine for Large Moulds 



Fig. 12. Tunnel Seg- 
ment Mould — Upper half 
or Cope — Made on a 
42"x97" plain jolt-mould- 
ing machine. 




Fig. 13. Tunnel Segment 
Casting weighing 1500 pounds, 
used in making tunnel linings 
for the New York subway 
system. 

PRODUCTION 



Method of Moulding 


No. 
Men 


Hours 


Quan. 

Moulds 


% 

Increase 




2 


9 


7 








Cope— 42"x97" Plain Tolt .. . 


2 


9 


14 




Drag-^2"x97" Plain Jolt 


100% 


Cope— 42"x97" Plain Jolt 

Drag— 42"xl06" R. 0. Jolt 


! 6 


9 


*141 


670% 



With sand conveying system. 



14 


foundry Moulding Machines and Pattern Equipment 










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Fig. 14. Railway Truck Frame Steel Casting — Weight 470 pounds. The 

standardization of railway equipment has resulted in large quantity pro- 
duction of the various castings. 

The production figures given below are based on using two machines 
of the Roll-Over Jolt type — one for the lower or drag half and the other 
for the upper or cope half of the mould. 



PRODUCTION 



With sand conveying system. 



Method of Moulding 


No. 

Men 


Hours 


Quan. 
Moulds 


% 

Increase 




5 


9 


IS 










Cope— 42"x97" Plain Jolt 

Drag— 42"x97" Plain Jolt 


5 


9 


*40 


166% 


Cope-^2"xl06" R. O. Jolt 

Drag— 42"xl06" R. 0. Jolt 


'.'. 7 


9 


*120 


470% 



Roll-Over Jolt-Moulding Machine for Large Moulds 



The shipbuilding industry 
has not attained the quantity 
production shown on the pre- 
ceding pages, yet a very great 
saving can be made by the use 
of moulding machinery on 
smaller quantity production as 
is shown in the following tabu- 
lations. 



The production figures given 
below are based on making the 
cope and drag moulds on the 
same machine. 




Fig. 15. Marine Engine Cylinder 
Head— Weight 2400 pounds. 



PRODUCTION 



Method of Moulding 

Without Machine 

Cope— 72"x72" Plain Jolt. 
Drag— 72"x72" Plain Jolt. 

Cope— 60"x92" R. O. Jolt. 
Drag— 60"x92" R. O. Jolt. 



No. 
Men 



Quan. % 

Hours Moulds Increase 



9 1 

9 2 100% 

9 3 200% 



16 



Foundry Moulding Machines and Pattern Equipment 




^t 



Fig. 16 



Marine Engine Column — Weight 4000 pounds. 

Where the quantity of castings required from one pattern is not 
sufficient for continuous production, or even for a full day's production, 
any number of different patterns can be used during the day. The 
changing of the pattern on the Roll-Over Jolt-Moulding Machine re- 
quires only a few minutes of time. 



The production figures given below are based on making the cope 
and drag moulds on the same machine. 



PRODUCTION 



Method of Moulding 


No. 
Men 


Hours 


Quart. 
Moulds 


% 

Increase 




4 


9 


1 








Cope— 42"x97" Plain Jolt 

Drag-^12"x97" Plain Jolt 


4 


9 


2 


100% 


Cope— 66"xl50" R. 0. Jolt 

Drag— 66"xlS0" R. 0. Jolt 


! 4 


9 


5 


400% 



Roll-Over Jolt-Moulding Machine for Large Moulds 



17 



A large number of ma- 
chine tool castings are adapt- 
able for machine moulding, 
particularly on the Roll-Over 
Jolt type of machine. 

In some instances, where a 
casting does not readily lend 
itself to machine moulding, a 
slight change can be made in 
the design without impairing 
its utility or strength, thereby 
making it possible to mould on 
machines. 



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Fig. 17 

Planer Housing Casting — Weight 
5000 pounds. 



The production figures given below are based on making the cope 
and drag moulds on the same machine. 





PRODUCTION 








Method of Moulding 


No. 
Men 


Hours 


Quan. 

Moulds 


% 

Increase 


Without Machine 


4 


9 


1 




Cope— 72"x72" Plain Jolt... 
Drag— 72"x72" Plain Jolt... 


'.'.'.'.'.'. 4 


9 


2 


100% 


Cope— 66"xlS0" R. 0. Jolt. 
Drag— 66"xl50" R. 0. Jolt. 


'.'.'.'. '. '. 4 


9 


5 


400% 



18 



Foundry Moulding Machines and Pattern Equipment 



Milling Machine Column. Weight 
of Casting — 700 pounds. 

A 45"x72" Roll-Over Jolt- 
Moulding Machine made both 
the upper or cope half and lower 
or drag half of the mould for 
producing this casting. 



The production figures given 
below are based on making the 
cope and drag moulds on the same 
machine. 



KJ 





Fig. 18 



PRODUCTION 



Method of Moulding 


No. 
Men 


Hours 


Ouan. 

Moulds 


% 

Increase 


Without Machine 


4 


9 


4 








9 


8 




Drag— -54"x66" Plain Jolt 


4 


100% 


Cope^5"x72" R. 0. Jolt 

Drag— 4S"x72" R. 0. Jolt 


'.'. 4 


9 


14 


250% 



Roll-Over Jolt-Moulding Machine for Large Moulds 



19 



A Milling Machine Base Casting 
made on a Roll-Over Jolt-Mould- 
ing Machine having an over-all 
flask capacity of 45" in width by 
72" in length. This machine is 
capable of jolting and rolling over 
half moulds up to 4,000 pounds in 
weight. 




Fig. 19 
Weight of Casting— 1040 pounds. 



The production figures given below are based on making the cope 
and drag moulds on the same machine. 



PRODUCTION 



Method of Moulding 


No. 
Men 


Hours 


Quan. 

Moulds 


% 

Increase 




3 


9 


4 










Cope — 54"x66" Plain Jolt 

Drag— 54"x66" Plain Jolt 


3 


9 


8 


100% 


Cope— 45"x72" R. O. Jolt 

Drag— 4S"x72" R. O. Jolt 


'.'. 3 


9 


18 


350% 



20 Foundry Moulding Machines and Pattern Equipment 




Fig. 20 



Milling Machine Table Casting — Weight 500 pounds. 

A 4S"x72" Roll-Over Jolt-Moulding Machine made the moulds for 
producing this casting. Its simplicity in design makes possible a large 
production by hand moulding, yet a very large increase has been obtained 
by machine moulding, as noted in the following tabulation. 



The production figures given below are based on making the cope 
and drag moulds on the same machine. 





PRODUCTION 








Method of Moulding 


No. 
Men 


Hours 


Quan. 
Moulds 


% 

Increase 




3 


9 


11 










Cope^l2"x60" Plain Jolt. . 
Drag— 42"x60" Plain Jolt.. 


!"!.'!! 3 


9 


18 


64% 


Cope— 45"x72" R. 0. Jolt.. 
Drag— 45"x72" R. O. Jolt. . 


'.'.'.'.'.'.'. 3 


9 


32 


190% 



22 Foundry Moulding Machines and Pattern Equipment 




Fig. 21. A 34"x64" Roll-Over Jolt-Moulding Machine, having a lifting 
capacity of 2,000 pounds. 



CHAPTER III 

Roll-Over Jolt-Moulding Machine for Medium 
Size Moulds 

The medium size Roll-Over Jolt-Moulding Machine, rang- 
ing in capacity from 1,000 to 2,000 pounds, is adapted for 
producing a large variety of castings, a number of which are 
illustrated on the following pages. 

The operations performed are jolting, rolling over the flask, 
lowering the mould on a receiving table, and drawing the pat- 
tern. These operations are accomplished by the use of com- 
pressed air at a pressure of 80 pounds per square inch. 

The pattern draw on a machine of this type should be posi- 
tive and extremely accurate. In some instances manufacturers 
require a micrometer test from each machine before shipment, 
the variation being held to less than .0005" per inch of travel. 

Lubrication is of the utmost importance ; therefore, the jolt- 
ing valve and piston should be equipped with a forced feed oiling 
system or other means of applying sufficient lubrication. Wher- 
ever possible, all working parts should be incased to prevent the 
entrance of sand, grit, etc. 

In order to more clearly set forth the advantages to be 
gained by the use of the Jolt-Moulding methods, a tabulation has 
been made showing the machine best adapted for producing the 
cope and the drag, also the production that can be obtained by the 
use of the two different styles of Jolt-Moulding Machines. 

The tabulation shows clearly that the greatest production is 
accomplished by the machine that performs mechanically all the 
operations required to make the mould. 

On page 9 a description of this type of machine is given, 
together with complete details of the operation, and the reader 
should refer to this description for detailed information. It 
should, however, be here stated that the operation of this ma- 
chine, when producing a mould, is as follows : 

First, the empty flask is placed over the pattern on the roll- 
over table of the machine; it is now ready for the sand, which 



24 Foundry Moulding Machines and Pattern Equipment 

should fill the flask completely with a heap of 3" or 4" above 
the top of the flask; the compressed air now admitted to the 
jolting cylinder rams the mould in from 20 to 40 blows, requiring 
8 to 16 seconds of time. While the jolting of the mould is in 
process, it is well to push the heap of sand above the flask that 
is being jolted, to the edges and corners of the flask, in order 
that the sand may be well packed into these places before the 
jolting action is complete. The loose sand at the top is then 
''butted off," the bottom board and flask clamped to the roll-over 
table, after which it is rolled over by applying compressed air 
to the roll-over or draw cylinder. The rolling-over action having 
been completed, the mould is then lowered and comes to rest 
above the receiving car, which is run in place while the mould is 
being rolled over. The automatic leveling pins, coming in con- 
tact with the uneven surfaces of the bottom board, are now 
clamped by the use of one lever, after which the mould is ready 
to have the pattern withdrawn. This is accomplished by first 
releasing the clamps required in rolling over, and then the air 
applied to the roll-over or draw cylinder, which causes the pat- 
tern to be steadily and carefully withdrawn from the sand. 

It is important, when providing the equipment for this par- 
ticular type of machine, to give particular attention to what is 
known as the flask space, provided for on the roll-over table. 
The parts to be occupied by the flask space include: First, the 
pattern-plate; second, the flask; third, the total height of the 
bottom board; fourth, the amount of filling blocks, or the addi- 
tional thickness of the pattern-plate that is required to fill the 
space unoccupied by the thickness of the first three parts men- 
tioned. 

The dimension of the flask space is constant for each machine 
and regardless of the combined thickness of the first three require- 
ments, the fourth requirement must be met in order to produce 
a properly working machine. 

After the mould has been jolted, rolled over and again low- 
ered on the receiving car, it should come in contact with the 
automatic leveling pins, depressing them a slight distance, about 
]/\" to Y%' being the desired amount. While the mould is now 



Roll-Over Jolt-Moulding Machine for Medium She Moulds 25 



at rest and hanging freely in this position, the flask equipment 
occupying the flask space must not be so great as to exceed the 
proper dimension given, for if it does, the bottom board, which 
is clamped to the mould, will then come in contact with the 
frame of the leveling car, in which case proper alignment could 
not be obtained. In other words, after the mould has been 
rolled over and lowered to a position of rest above the receiving 
car, there should be no part of the bottom board in contact with 
the receiving car except that portion coming in contact with the 
depressible leveling pins which, however, should not be depressed 
to the full depth of their stroke. 



26 



Foundry Moulding Machines and Pattern Equipment 




Fig. 22 



Automobile Cylinder with Upper Half of Crank Case 
cast en bloc — Made on a Roll-Over Jolt-Moulding Machine. 

This view shows the pattern drawn from the mould, which 
is deposited on the run-out car and ready for the crane to re- 
move to the foundry floor for setting the core. 

After sufficient drags have been made to begin core-setting, 
the drag pattern is removed from the machine and the cope pat- 
tern substituted. This changing of pattern consumes about five 
minutes in time, as only four bolts are used in securing it to the 
roll-over table. 

Foundries producing these castings in large quantities find 
it advisable to use two machines in producing the mould — one 
to be used in making the cope half and the other the drag half 
of the mould. 



Roll-Over Jolt-Moulding Machine for Medium Size Moulds 27 




Fig. 23 



Automobile Cylinder en bloc. Weight 175 pounds. 

The production figures given below are based on making the cope 
and the drag on the same machine. 



PRODUCTION 



Method of Moulding 


No. 
Men 


Hours 


Quan. 
Moulds 


% 

Increase 


Without Machine 


2 


9 


2 










Cope— 36"x48" Plain Jolt 

Drag— 36"x48" Plain Jolt 


'.'. 2 


9 


4 


100% 


Cope— 34"x64" R. 0. Jolt 

Drag— 34"x64" R. 0. Jolt 


4 


9 


48 


1150% 



2<S 



Foundry Moulding Machines and Pattern Equipment 



An Automobile Truck Wheel 
produced in a steel foundry. 

Beginning work in the morning, 
10 to 15 drags are made, per- 
mitting the core-setter to start 
work. The drag pattern is then 
removed from the machine and 
the cope half of the mould is 
made. Rotation in this manner 
makes possible the closing of the 
mould before the floor is com- 
pletely filled. 

If the quantity is sufficient, it 
is advisable to use two machines, 
one for the cope and one for the 
drag. 




Fig. 24 
Weight 240 pounds 



The production figures given below are based on making the cope 
and drag moulds on the same machine. 





PRODUCTION 








Method of Moulding 


No. 
Men 


Hours 


Quan. 
Moulds 


% 

Increase 




3 


9 
9 


9 

18 










Cope — 42"x50" Plain Jolt . . 






Drag— 42"x<50" Plain Jolt . . 


3 


100% 






Cope— 34"x64" R. 0. Jolt. . 
Drag— 34"x64" R. 0. Jolt.. 


'.'.'.'.'.'.'. 3 


9 


45 


400% 



Roll-Over Jolt-Moulding Machine for Medium Size Moulds 



29 



Remarkable progress is being 
made on tractor work and the 
large quantity of castings re- 
quired makes machine moulding a 
necessity. 




■' K _■ 



A pair of 34"x64" Roll-Over 
Jolt-Moulding Machines were used 
in obtaining the production noted 
below, one making the cope half 
and the other the drag half of 
the mould. 






Fig. 25 

Tractor Sprocket Wheel — 
Weight 115 pounds. 



PRODUCTION 



Method of Moulding 


No. 

Men 


Hours 


Quan. 

Moulds 


% 

Increase 




6 


9 


30 








Cope— 36"x48" Plain Jolt 

Drag— 36"x48" Plain Jolt 


6 


9 


60 


100% 


Cope— 34"x64" R. 0. Jolt 

Drag— 34"x64" R. 0. Jolt 


'.'. ■ 6 


9 


125 


317% 



30 



Foundry Moulding Machines and Pattern Equipment 




Fig. 26 

The Upper Half of Liberty Motor Aluminum Crank Case — made on a 
34"x70" Roll-Over Jolt-Moulding Machine. 

The large production noted in the tabulation below was obtained 
with a pair of these machines, one making the upper or cope half and the 
other the lower or drag half of the mould. 

Weight of casting 100 pounds. 
PRODUCTION 

No. Quan. % 

Method of Moulding Men Hours Moulds Increase 

Without Machine 8 9 16 

Cope— 42"x60" Plain Jolt 

Drag— 42"x60" Plain Jolt , 8 9 32 100% 

Cope— 34"x70" R. O. Jolt 

Drag— 34"x70" R. O. Jolt 8 9 102 540% 



Roll-Over Jolt-Moulding Machine for Medium Sise Moulds 



31 



Steel Casting of a lower Ball 
Race for 6 ton Armored Truck. 

Made on a 32" x 54" Roll-Over 
Jolt-Moulding Machine. A dense 
and uniform casting is very essen- 
tial in work of this kind. Loss 
from defective castings is reduced 
to a minimum by machine mould- 
ing, thus making a saving in labor 
and metal and also increasing the 
production. 




Fig. 27 
Weight 230 pounds. 

Production based on using one machine for both the cope and the 
drag half of the mould. 



PRODUCTION 



Method of Moulding 


No. 
Men 


Hours 


Quan. 
Moulds 


Increase 




3 


9 


20 










Cope— 24"x36" Plain Jolt 

Drag— 24"x36" Plain Jolt 


3 


9 


32 


60% 








Cope— 32"xS4" R. 0. Jolt 

Drag— 32"x54" R. 0. Jolt 


'.'. 3 


9 


45 


125% 



32 Foundry Moulding Machines and Pattern Equipment 



Milling Machine Drive Pulley. 



Weight of casting 200 pounds. 




Fig. 28 



Production based on using one machine for both the cope and the 
drag half of the mould. 

PRODUCTION 



Method of Moulding 


No. 
Men 


Hours 


Quan. 

Moulds 


% 

Increase 


Without Machine 


3 


9 


20 




Cope— 24"x36" Plain Jolt.... 
Drag— 24"x36" Plain Jolt.... 


'. '. '. '. '. 3 


9 


32 


60% 


Cope— 32"x54" R. 0. Jolt 

Drag— 32"x54" R. 0. Jolt 


3 


9 


45 


125% 









Roll-Over Jolt-Moulding Machine for Medium Size Moulds 33 













O 












r /6- 








— 




S 


406rrr* 






5* 






s 


Y 


r 


h. 


















1 


' 














Fig. 29 

Milling Machine Headstock. Weight of casting 250 pounds. 

Production based on using one machine for both the cope and the 
drag half of the mould. 

PRODUCTION 

No. Quan. % 

Method of Moulding Men Hours Moulds Increase 

Without Machine 3 9 18 

Cope— 24"x36" Plain Jolt 

Drag— 24"x36" Plain Jolt 3 9 24 33yi% 

CoDe— 32"x54" R. O. Jolt 

Drag— 32"x54" R. O. Jolt 3 9 38 111% 



34 Foundry Moulding Machines and Pattern Equipment 



Casting used in the Shipbuilding 
Industry. 




Towing Chock. Weight 
500 pounds. 



Fig. 30 

Production based on using one machine for both the cope and the 
drag half of the mould. 

PRODUCTION 



Method of Moulding 


No. 

Men 


Hours 


Quan. 

Moulds 


% 

Increase 




4 


9 


4 










Cope— 36"x48" Plain Jolt 




9 


8 




Drag— 36"x48" Plain Jolt 


4 


100% 


Cope— 34"x64" R. 0. Jolt 

Drag— 34"x64" R. 0. Jolt 


'.'. 4 


9 


20 


400% 



Roll-Over Jolt-Moulding Machine for Medium Size Moulds 



35 



Casting used in the Ship- 
building Industry 




Fig. 31 

Combination Mooring Timberhead. 



Production based on using one machine for both the cope and the 
drag half of the mould. 





PRODUCTION 










Method of Moulding 


No. 
Men 


Hours 


Quan. 
Moulds 


% 

Increase 


Without Machine 


4 


9 




5 




Cope— 42"x60" Plain Jolt.. 




9 




9 




Drag-42"x60" Plain Jolt.. 


4 


80% 


Cope— 34"x64" R. 0. Jolt. 
Drag— 34"x64" R. 0. Jolt. 


..... .7. 4 


9 




22 


340% 



36 Foundry Moulding Machines and Pattern Equipment 



Shipbuilding Industry 




Fig. 32. 8"xl0" Single Drum Hoisting Engine. 

A double cylinder engine used principally for mooring on the after 
end of the large ore boats. 




Fig. 33. Flanged Pipe Fittings. 

Made principally of semi-steel or cast iron 



Roll-Over Jolt-Moulding Machine for Medium Size Moulds 



37 



Shipbuilding Industry 




Fig. 34. 10"xlO" Globe Windlass Engine. 



The photographs on this and the opposite page show the construction 
of a marine deck engine and windlass in detail. 

Practically all castings, such as the winch head, winding drum, brack- 
ets, cylinder, plate, bed, pipe fittings, etc., are adaptable for moulding on 
the Roll-Over Jolt type of machine. 



38 



Foundry Moulding Machines and Pattern Equipment 



Shipbuilding Industry 



CASTINGS HBQ'D 


MACHIIIB MOULDING 




HAND MOULDING 


SAVING 




Name 


Suant 


R.O. 
Maoh. 


Out- 
Pat 


No. 

Men 


Cost 

Each 


Out- 
put 


No. 
Men 


Cost 

Eaoh 


Value 


* 


Man 
Days 


IS" Bits - 


600 


46 n x72" 
2 bx 


30 


4 


$ .70 


- 


2 


$6.25 


$2730. 


86 


520 


Core 


2400 


32 n x64 n 


140 


2 


.086 


16 


1 


.375 


693. 


77 


116 


TOTAL 








6 






3 




3423 




636 


9" Bits - B 


1800 


45"x72" 
2 bx 


35 


4 


.60 


3 


2 


3.50 


5220. 


83 


992 


Core 


7000 


32"x64" 


140 


2 


.086 


36 


2 


.33 


1780. 


74 


296 


TOTAL 








6 






4 




7000. 




1288 


6" Bit - A 


600 


34"x64" 


40 


3 


.413 


6 


8 


1.75 


802. 


76 


155 


Cora 


1200 


22"x37" 


150 


1 


.04 


26 


1 


.24 


240. 


83 


40 


TOTAL 








4 






3 




1042. 




195 


Mooring Rings 
Dwg. H-52 #a 


1200 
300 


34"x64" 


40 


4 


.525 


9 


6 


3.50 


4462. 


85 


850 


Core #a 

~!-o 


2400 


22"x37 u 


100 


2 


.12 


18 


1 


.33 


630. 


63 


107 


TOTAI 


















5092. 




957 



Fig. 35 



Tabulation showing production by machine and by hand moulding on a 
number of ship castings. The total value of saving by machine moulding 
on the quantity noted amounts to $16,557.00. 



The total amount of labor by hand moulding 3,767 man days 

The total amount of labor by machine moulding 691 " " 

Saving in labor 3,076 " " 

Average percentage of saving 81% 



Roll-Over Jolt-Moulding Machine for Medium Size Moulds 



39 



Shipbuilding Industry 



CASTISGS HSQ'D 


MACHINE MOULDING 


HAND 


MOULDING 




SAVING 


llama 


Mach 


Out 
Put 


Ho 
Men 


Cost 

Each 


Out 
Put 


No 
Men 


Coat 
Each 


Value 


58 


Man Days 
Per Mo. 


Driving Collar 
(28" aia.) 


32 n x64 n 


40 


2 


.26 


3 


1 


3.50 


3.24 


93 


294 


Windlas Side 


32"x64" 


24 


2 


.44 


3 


1 


3.60 


3.06 


87 


166 


3everal Small El- 
bows; Ash Gun 
Baffle Plate; Dis- 
charge Valve - 
Chest liner 


32"x54'' 
22"x37" 


40-50 

of any 

of 
these 


8 


.21 
.26 


4 

6 


2 


1.75 

to 
2.62 


1.54 

to 
2.36 


88 
to 

90 


620 



Fig. 36 



Total saving per month $8,076.64 

Total saving in labor 1,534 man days 

Average percentage of saving 84% 



CASTINGS RSQ'D 


MACHINE MOULDING 


HAND MOULDING 


SAVING 




Kane 


R.O. 

Mach 


Out 

Put 


No 
Men 


Coat 
Each 


Out 

Put 


No 

Men 


Cost 
Each 


Value 


% 


Man Days 
Per Mo. 


Housing Slides 


34"x64" 


40 


3 


.41 


4 


1 


1.50 


1.09 


73 


182 


Winch Head 

(Cetg. 24" dia. Bot. 

( " 18" " top 


34"x64" 


40 


3 


.41 


2 


2 


6.25 


4.84 


92 


962 


Anchor Chain 
8topper 


34"x64" 


12 


3 


1.38 


1 in 
1-2/3 
daya 


Z 


7.00 


6.62 


80 


338 



Fig. 37 



Total saving per month $8,347.00 

Total saving in labor 970 man days 

Average percentage of saving 89% 



40 



Foundry Moulding Machines and Pattern Equipment 




Roll-Over Jolt-Moulding Machine for Medium Size Moulds 41 




42 Foundry Moulding Machines and Pattern Equipment 



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Roll-Over Jolt-Moulding Machine for Medium Size Moulds 



43 




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44 Foundry Moulding Machines and Pattern Equipment 



- ill 






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It''" 
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Roll-Over Jolt-Moulding Machine for Medium Size Moulds 



45 




U 6 

S -so 

C 

a « 
o ~ 

*■§ 

s s 

08 O 



<3 en 



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46 Foundry Moulding Machines and Pattern Equipment 




U 



48 



Foundry Moulding Machines and Pattern Equipment 



1 
1 ' i--}— - 












H' v " 


























A 






M 




Fig. 45 



A 22 x37 Roll-Over Jolt-Moulding Machine, having a lifting 
capacity of 800 pounds, showing foundation setting. 



CHAPTER IV 

Roll-Over Jolt-Moulding Machine for 
Small Moulds 

The good results produced from the use of Jolt-Moulding 
machines on the large and medium sized work, creates a demand 
for a Jolt-Moulding Machine that will quickly handle the many- 
small patterns adaptable to jolt-moulding. The machine should 
be small, self-contained and protected from sand and grit. 

It should not require a pit in which to set, nor should the 
falling sand from the flask obstruct its working. 

The different operations of the machine should be performed 
in the simplest manner possible and without consuming an ex- 
cessive amount of time. Especially is this true of the operations 
other than the jolting of the mould, as when these operations are 
compared with the operations of a moulder making a mould on the 
floor, it is evident that he does not spend much time in clamp- 
ing the bottom board onto the flask, or the rolling over of the 
mould, and, therefore, these operations when performed on the 
machine and viewed from the standpoint of time, alone, require 
the utmost speed in the operation of the machine. However, 
there enters at this point an element not thus far considered, 
i. e., while the moulder can perform a few of the individual 
operations when making the mould on the floor, in the same time 
or even faster than the time of the machine, nevertheless, it is 
the performing of these operations throughout the entire day 
that consumes the vitality and strength of the moulder, and it 
is a fact that in the latter part of the day his operations are not 
nearly as speedy as they were at the beginning of the day's 
work, while on the other hand, the operations performed by 
machine power are constant throughout the entire day and with 
very little effort on the part of the operator. 

There was a time, now past, when these most vital points 
did not require the consideration that must now be given them, 
for at that time there was an abundance of manpower available; 



50 Foundry Moulding Machines and Pattern Equipment 

workmen could be had to perform these tasks at a low rate 
of wages, and the workman, in order to secure a livelihood and 
perform the tasks required of him if he was to retain his posi- 
tion, produced, at the expense of breaking- down his health and 
strength, a large day's work. Conditions, however, have changed 
and those days have seemingly passed forever, as the workman 
has come to a position where he is satisfied that he should produce 
the necessities of a livelihood without the hard work which in 
the past has been so necessary to maintain a satisfactory foundry 
production. He is beginning to realize that the manufacturer 
and foundryman should furnish him with machines that will per- 
form the heavy and drudging part of the day's work, without 
exacting the maximum of his effort, and yet produce equal or 
greater results than those obtained by the old time methods. 

For producing the smaller size of what we have termed 
"Small Moulds," there has been a demand for a Roll-Over 
Jolt-Moulding Machine mounted on wheels, either operating 
on the foundry floor or on Tee rails, placed in the foundry 
floor in such a manner that the machine can be conveyed 
from one end of the floor to the other. The claim is made 
that the distance the moulds are carried from the machine to the 
floor being less than when the machine is permanently located 
in position on the foundry floor, a greater production can be 
obtained with less effort on the part of the operators. Others 
maintain that the machine permanently located has an advantage 
over the portable machine, claiming that the time and energy 
consumed in moving the machine is equal to that required in 
carrying the moulds the short distance further. This again is 
largely a matter of individual preference and should be deter- 
mined by the conditions in the foundry in which the machine is 
to be used. Many foundries, using this particular type of ma- 
chine for small work, prefer to set it in a permanent location 
under the chute of a sand-conveying system, which has been 
found a highly desirous installation in foundries producing cast- 
ings in large quantities, while others prefer to make use of the 
available sand-cutting machines in bringing the sand, after it has 
been tempered, from the floor into a pile alongside the mould- 



Roll-Over Jolt-Moulding Machine for Small Moulds 51 

ing machine, where it is then readily shoveled into the flask 
before the mould is made. 




Fig. 46 

A Stripping-Plate Jolt-Moulding Machine with Stripping Plate 
and Patterns Mounted. 



While the Roll-Over Jolt-Moulding Machine is best adapted 
for general all-around small foundry work, nevertheless there 
are some patterns from which a large quantity of castings are 
to be made which can be best and most quickly made by ma- 
chines without the roll-over operation. This machine is known 
as the Stripping-Plate Jolt-Moulding Machine, and as the name 
suggests, is used in connection with a stripping-plate. Such 
a machine, however, requires the highest grade of pattern 
equipment and cannot be used economically, considering the 
cost of equipment necessary, unless the quantity to be pro- 
duced from the pattern runs well into the thousands. Such a 
machine is illustrated above, equipped with a stripping plate and 
set of patterns. Many of the large automobile manufacturers, 
producing automobiles running into the thousands per day, have 



52 Foundry Moulding Machines and Pattern Equipment 

profitably used a highly specialized combination machine, which 
embodies a jolting operation, a squeezing operation, and the 
operation of rapidly drawing the mould from the pattern by 
means of a stripping plate. 

The Roll-Over Jolt-Moulding Machine shown at the be- 
ginning of this chapter is operated by compressed air at 80 
pounds per square inch; its functions are jolt-ramming, rolling 
over the mould, lowering the mould on the swing-out table and 
then drawing the pattern from the sand. After these operations 
are performed, the mould is swung clear of the machine, as is 
shown in the cuts on the following pages. 

The numerous castings and foundry floors shown in this 
chapter will give a good idea of the production obtained and will 
suggest to the reader the great possibilities of machine moulding 
when applied to this class of work. 

The castings produced by this type of machine are true to 
pattern, uniform in weight and, when they are machined by 
holding in jigs, have a decided advantage over the ones made 
by hand ramming. 



Roll-Over Jolt.-Moulding Machine for Small Moulds 



53 




.5 C 

-a -a 



9 § 



2 ? "S 



^ J-i U 

> o <u 

H i! 

I "O rt 

2 o J: 

►J- <u 

.S 3 > 

U S o 

1 M 



< "> 



l-» J3 J3 

^ H H 



54 Foundry Moulding Machines and Pattern Equipment 



W 



fe= bft ^% & 



Automobile Cylinder Head. 



=w— r 



rV~K /^vrK f +v+\ r^^K /4\^K r S^S 



JS 



_0 



■fi~ 



Weight 38 pounds 




Fig. 48 



Production based on making both the cope and the drag half of the 
mould on the same machine. 



Method of Moulding 


No. 
Men 


Hours 


Quant. 

Moulds 


% 

Increase 


Without Machine 


3 


9 


30 




Cope— 20" x 27" Plain Jolt 

Drag— 20" x 27" Plain Jolt 


3 


9 


60 


100% 


Cope— 22" x 37" R. 0. Jolt 

Drag— 22" x 37" R. 0. Jolt 


3 


9 


200 


567% 



Roll-Over Jolt-Moulding Machine for Small Moulds 



55 



Steel Casting Bracket for 6-Ton 
Armored Truck. 



Weight 50 pounds. 




Fig. 49 



Production based on making both the cope and the drag half of 
mould on the same machine. 



PRODUCTION 



Method of Moulding 


No. 
Men 


Hours 


Quant. 
Moulds 


% 
Increase 




3 


9 


11 










Cope— 20" x 27" Plain Jolt 

Drag— 20" x27" Plain Jolt 


;.' 3 


9 


22 


100% 


Cope— 22" x 37" R. 0. Jolt 

Drag— 22" x 37" R. 0. Jolt...... 


". 3 


9 


36 


227% 



56 Foundry Moulding Machines and Pattern Equipment 



Steel Casting Sprocket for 
6-Ton Armored Truck. 



ssJ 



y " 






/ 



A 



Weight 125 pounds. 




Fig. 50 



Production based on making both the cope and the drag half of 
mould on the same machine. 

PRODUCTION 

No. Quant. % 

Method of Moulding Men Hours Moulds Increase 

Without Machine 3 9 10 

Cope— 20" x 27" Plain Jolt 

Drag— 20" x 27" Plain Jolt 3 9 18 80% 

Cope— 22" x 37" R. O. Jolt 

Drag— 22" x 37" R. O. Jolt 3 9 32 220% 



Roll-Over J olt.-M oulding Machine for Small Moulds 



57 






Fig. 51 
High Pressure Steam Trap. 



Weight 61 pounds 



Production based on making 
both the cope and the drag 
half of mould on the same 
machine. 






PRODUCTION 








Method of Moulding 


No. 
Men 


Hours 


Quant. 
Moulds 


% 

Increase 


Without Machine 


2 


9 


18 




Cope— 20" x 27" Plain Jolt. 
Drag— 20" x 27" Plain Jolt. 


'. .'.'.'.'. 2 


9 


27 


50% 






Cope— 22" x 37" R. 0. Jolt. 
Drag— 22" x 37" R. 0. Jolt. 


'.'.'.'.'.'. 2 


9 


42 


133% 



58 Foundry Moulding Machines and Pattern Equipment 



Timberhead Casting. 

Used in the Shipbuilding 

Industry. 




Fig. 52 

Production based on making both the cope and the drag half of 
mould on the same machine. 





PRODUCTION 








Method of Moulding 


No. 
Men 


Hours 


Quant. 
Moulds 


% 

Increase 


Without Machine 


3 


9 


21 




Cope— 18" x 18" Plain Jolt. 
Drag — 18" x 18" Plain Jolt. 


3 


9 


36 


71% 






Cope— 22" x 37" R. 0. Jolt. 
Drag— 22" x 37" R. 0. Jolt. 


.' .' .' .' ! .' 3 


9 


48 


130% 



Roll-Over Jolt-Moulding Machine for Small Moulds 



59 



Cleat Casting. 

Used in the Shipbuilding 

Industry. 







/~)OZ<m.m 


_J 


S 


L_ 








^~ — -i ti 




1 J 


n 




T 


. '«" 




406** »» 


r s~ 


"■ — -^ V 


(^ 


r ■ 1 ■ 











Fig. 53 



Production based on making both the cope and the drag half of 
mould on the same machine. 





PRODUCTION 








Method of Moulding 


No. 
Men 


Hours 


Quant. 

Moulds 


% 

Increase 




3 


9 


36 










Cope— 18" x 18" Plain Jolt. 
Drag— 18" x 18" Plain Jolt. 


...... 3 


9 


60 


67% 






Cope— 22" x 37" R. 0. Jolt. 
Drag— 22" x 37" R. 0. Jolt. 


'.'.'.'.'.'. 3 


9 


100 


180% 



60 



Foundry Moulding Machines and Pattern Equipment 




Roll-Over Jolt-Moulding Machine for Small Moulds 



61 




62 Foundry Moulding Machines and Pattern Equipment 




CHAPTER V 



The Jolt-Moulding Machine in Aluminum and 
Brass Foundries 

The Jolt-Moulding Machine, having had its early develop- 
ment in the iron and steel foundry, was somewhat slow in being 
accepted as a machine which would produce the proper kind 
of moulds for brass and aluminum castings. The pouring 
-^ r . jwW conditions in the 

aluminum and brass 
foundry are different 
from those in an iron 
or steel foundry, inas- 
much as the pouring 
in the aluminum and 
brass foundries is tak- 
ing place throughout 
the entire working 
day. 

This method of 
operation made pos- 
sible the production 
Fig. 57. Liberty Motor Crank Case — of castings in multiple 

Upper and Lower Half. numbers with an ex- 

ceptionally small number of flasks and with a minimum of floor 
space ; and then again, some difficulty was experienced in 
securing a jolt-moulding machine which would produce a blow 
suitable for the ramming of a mould of uniform density, and 
still leave the parts of the mould soft enough for the pouring 
of the aluminum. It was found, however, that the Roll-Over 
Jolt-Moulding Machine, by proper adjustment of its stroke and 
with proper pattern and flask equipment, could be made to pro- 
duce the desired blow, which has resulted in many of the large 
brass and aluminum foundries of the United States being 
equipped with this type of machine. Perhaps it required the 
stress of war conditions, with the necessity for a large produc- 
tion with a minimum consumption of man-power, to force the 
development into a perfection of operation such as has rarely 
been experienced in the foundry industry. 




64 Foundry Moulding Machines and Pattern Equipment 

The views in this chapter were made in the plant of the 
Aluminum Castings Company, Cleveland, Ohio, and show the 
complete process of moulding and easting the Liberty Motor 
Crank Cases. 

When the American engineers designed and began building 
the Liberty Motors in quantity for Government aeroplanes, it 
was with the full realization of the possible difficulties 
that would be encountered before all of the many details 
were perfected and the engine pronounced a success, both 




Fig. 58. Pattern Mounted on Roll-Over Jolt Machine. 

from the viewpoint of reliability of operation and the practica- 
bility of its adaptation to manufacturing methods. The 400 H.P., 
which the motor was to develop, required materials, in fact de- 
manded materials, that would be absolutely perfect in their metal- 
lurgical qualities and of the highest grade of workmanship. 

Of the many different parts of the engine, the crank 
case is one that received a considerable amount of attention, as 
failure in this particular part practically meant complete destruc- 
tion of the engine. The inspection, therefore, was carefully made 
and the materials held strictly to the specifications. 



The Jolt-Moulding Machine in Aluminum and Brass Foundries 65 




Fig. 59. 



Jolting the Drag Half of the 
Mould. 



The aluminum foundries 
with the true Yankee spirit, 
began with a determined ef- 
fort to produce castings that 
would pass inspection and ful- 
fill all requirements of the spe- 
cifications. 

After the casting had 
been successfully produced, 
free from blowholes, cold 
shots, shrinkage strains, and 
internal stresses, the next 
question that confronted the 
foundry was one of produc- 
tion to meet the enormous re- 
quirements demanded by the Government's program. The same 
determination that produced the casting successfully from the 
metallurgical standpoint, also solved the problem of producing 
the quantities required per day. The Roll-Over Jolt-Moulding 
Machine was, after due consideration, decided upon as being the 
one best adapted to produce the moulds. 

An inside and an outside view of the casting are shown in 
Fig. 57. These views show clearly the construction of the casting, 
both of the top and bottom half. 

The pattern mounted on 
the pattern plate and attached 
to the table of the moulding 
machine is shown clearly in 
Fig. 58. It will also be noted 
in this view that a finished 
drag mould is on the run-out 
car of the machine. The bot- 
tom boards that were used 
are seen standing against the 
foundry wall. 

In Fig. 59 the flask is 
being filled with sand from 





- 


••flk* H 




■ 


' '^s 


•tm~ 


(f-vi , 


ea 1 




lIVi l 


'** 




'•\ ' 




. -r *v- 


^■L^^' 






Bffcft&fa ? 



Fig. 60. Butting Off the Cope Half of 
Mould. 



66 Foundry Moulding Machines and Pattern Equipment 




Fig. 61. Drag Half of Mould Ready for Setting the Cores. 




Fig. 62. Drag Half of Mould with Cores Set. 



The Jolt-Moulding Machine in Aluminum and Brass Foundries 67 



ms Jlfr 

«i ;.lHLj| 



Fig. 63. Making Cores on Small Jolt 
Machine. 



the chutes overhead, which 
are a part of the sand con- 
veying system with which this 
plant is equipped. 

In Fig". 60 the jolting op- 
eration of the cope half of the 
flask is completed and the 
workmen are "butting off" 
the loose sand on top of the 
mould, an operation which can 
be performed in eight or ten 
seconds of time. 

Too much emphasis can- 
not be placed upon the neces- 
sity of providing the proper 
attempting a large production. By 
61 it will be seen that the 
The flask is 



flask equipment when 
analyzing the flask shown in Fig. 
flask provided is one well adapted to their work 
made of aluminum, and the trunnion piece has been cast sepa- 
rately and provided with dovetailed slots at each end ; the purpose 
of these slots is to receive the loose pieces that are used as 
handles in case it is desired to carry the flask without a crane. 
Bolts are used for securing 
this trunnion piece to the 
flask. This Figure also shows 
a splendid detail of the drag 
half of the mould, after the 
pattern has been withdrawn 
and the mould set on the 
foundry floor. 

By referring to Fig. 62, 
this same drag half of the 
mould is shown with cores 
set and ready to receive the 
cope. 

There are six separate F ig. 64. Completing Moulds Ready for 
cores used in the body of the Pouring. 




Foundry Moulding Machines and Pattern Equipment 




Fig. 65. Shaking Out the Moulds. 



mould all practically the same 
in construction, and were 
made on a small Plain Jolt- 
Moulding Machine, as shown 
in Fig. 63. These cores were 
produced by first placing in 
the bottom of the core-box, a 
dry-sand slab in which had 
been placed suitable holding 
lugs to which the carrier 
handles are attached. The 
core-box is then filled with 
green sand and jolt-rammed. 
The shape of the core de- 



manded the hinge type of box which permitted the swinging of 
the box from off the core, after which it was carried to the green- 
sand core-racks. 

In Fig. 64 may be seen a row of moulds, part of which are 
completed and ready for pouring, while others at the farther end 
of the row are "shaken out" and ready for cleaning. The small 
core referred to above is here seen with the lifting handles in 
place, standing beside the drag half of the mould appearing in 
the foreground. 

Fig. 65 shows a close-up view of the distant end of the row 
of moulds shown in the preceding view. The sand has been 
shaken from the mould and the castings appear as they are 
before being sent to the chipping and cleaning room. 

The remarkable production obtained by the use of moulding 
machines on this casting is exceptional, as eight men produced 
102 moulds per day, the cope and drag being made on different 
machines. The best results obtained under former conditions 
was the production by eight men of 16 moulds per day. 

It should be noted also that the production from the hand- 
ramming method resulted in a scrap loss of 30%, while the scrap 
loss from the moulds made on the Roll-Over Jolt-Moulding 
Machine was less than 10%. 



70 



Foundry Moulding Machines and Pattern Equipment 




Fig. 66 

A 42" x 60" Plain Jolt-Moulding Machine having a jolting 
capacity of 7,000 pounds. 



CHAPTER VI 
Plain Jolt-Moulding Machines. 

In the early development of the jolt-ramming- method of 
moulding', the experiments were made on the machine now 
known as the Plain Jolt-Moulding Machine. These early experi- 
ments extended over a period of about fifteen years, finally re- 
sulting in a machine that is highly satisfactory for producing a 
large variety of castings. The Plain Jolt-Moulding Machines 
are used largely in the jobbing foundries which produce a large 
variety of many different sizes of castings, as well as in those 
manufacturing establishments which operate a foundry as a part 
of their plant, producing only the castings used for their require- 
ments. 

The foundry has been retarded somewhat in the use of mould- 
ing machines, because of the difficulty experienced in attempting 
to use the patterns which the patternmaker or the manufacturer 
sends to the foundry for its use. It is an unfortunate fact 
that neither the manufacturer nor the patternmaker is interested 
enough in the progress of the foundry to inquire as to whether 
or not the moulds are to be made on a moulding machine. Instead, 
in a large number of instances, the patterns are made without 
any consideration whatsoever being given as to how the moulds 
are to> be produced in the foundry and, therefore, are usually 
made in a manner such as would require their being moulded by 
hand on the bench or moulding floor. 

Inquiry by the patternmaker as to how the patterns are 
to be used would encourage the foundryman to equip his plant 
with machines ; and, likewise, if inquiry by the patternmaker were 
made of the manufacturer, as to how the pattern should be 
made, pointing out the fact that if made to be used for hand 
moulding the cost of his castings would be higher than if the 
pattern were made to be moulded on a machine, such an inquiry 
would immediately create a desire in the mind of the manufac- 
turer to know more about the possible saving in the cost of cast- 
ings, and investigation would be started which would eventually 



72 Foundry Moulding Machines and Pattern Equipment 

lead to his issuing an order to his patternmaker to make all his 
patterns so that they could be used on moulding- machines. This 
spirit of co-operation would be beneficial ; experience has demon- 
strated the fact that patterns can be made for machine moulding 
in a manner more substantial and at a less cost than when made 
for hand-ramming methods. 

The general use of the Plain Jolt-Moulding Machine in the 
plants above mentioned is due largely to the fact that it is pos- 
sible to produce a jolt-rammed mould from the old-style patterns 
furnished the foundry by the customer, with less expense to 
the foundry than mounting the pattern on a pattern plate in 
order to produce the mould. In many foundries, in order to 
jolt-ram the pattern that has been furnished them for hand- 
ramming, it is the practice to use the Plain Jolt-Moulding Ma- 
chine for jolt-ramming the drag only, in which case the pattern, 
if a flat back or split pattern, is placed upon the table of the 
machine without either bottom board or clamps ; the flask is then 
set over the pattern and filled with sand, and, when filled, holds 
the pattern in place while the mould is being jolt- rammed by 
machine power. The bottom board is then placed on the drag, 
after which it is rolled over and placed on the floor and the cope 
hand-rammed in the usual method. 

Other foundrymen first determine the range of flask sizes 
that is necessary in which to produce the output of their plant, 
and then provide several plates for the different sizes of flasks 
determined upon. These plates are provided with permanent 
center lines and other locating marks which make it a simple 
matter to mount the pattern that is furnished them by the cus- 
tomer. By this method it is possible to produce at the same time 
several castings of different sizes and shapes in the same mould. 

The results obtained from the use of the Plain Jolt-Moulding 
Machines in the plants above mentioned, were satisfactory and 
in advance of results that had previously been obtained, never- 
theless, an analysis of the work performed by the Plain Jolt 
Machine shows that there is a saving of only about 50% of the 
moulders' time in producing the mould, depending, of course, 
upon the manner in which the patterns are mounted. However, 



Plain Jolt^Moulding Machines 73 

it is evident that the Plain Jolt-Moulding Machine can only save 
the actual ramming time of the mould, as the rolling over of the 
mould and the drawing of the pattern must still be accomplished 
by a highly skilled artisan. The drawing of the pattern is a 
delicate operation as any unsteadiness of the moulder will break 
down the delicate projections of the sand, and it is rarely, if ever, 
that the pattern, regardless of size, is withdrawn from the sand 
in such a manner as to leave the mould perfect ; in most instances 
the sand is broken down in many places, which must be mended ; 
this again requires exceptional skill, and rarely, if ever, does 
the mended mould produce a smooth casting. The mending 
of the mould, in a large majority of cases, is so common among 
moulders, that even if the pattern is withdrawn from the mould 
without breaking the sand, the mending of the mould having 
become a fixed habit, the moulder immediately proceeds to use 
the trowel and slick tools to dress the mould with the same care 
that would be required if the mould actually needed mending. 

The construction of the Plain Jolt-Moulding Machine is 
comparatively simple, in fact the simplest of the many dif- 
ferent kinds of moulding machines in use. While the machines 
are of apparently simple construction, nevertheless the fact re- 
mains that in order to secure a machine that will produce the 
proper results, and give service over a period of years, thought 
should be given in the selection to secure a machine that not only 
has the above features, but in addition will be economical in oper- 
ation both in point of the amount of air and oil consumed, and 
the care required to keep the machine in operating condition. 

It is important that the design of a machine that will fulfill 
the above requirements should be one in which the working parts 
are fully protected and of ample size to reduce the wear to a 
minimum. The cylinder diameter and length on the Plain Jolt- 
Moulding Machine should be given careful consideration and 
made proportional to the table size, in order to secure a machine 
that will pack sand properly. The importance of this feature can- 
not be overestimated, as it is obvious that with the machine hav- 
ing a short piston, it would be difficult to secure the proper blow 
to produce a rapid packing of the sand, as the amount of working 



74 Foundry Moulding Machines and Pattern Equipment 

clearance between the bore of the cylinder and the diameter of 
the piston would, with the short piston, be multiplied many times 
at the extreme edge of the table. Such a machine very often 
produces, when moulding-, in addition to the jolting blow, because 
of the clearance referred to between the cylinder and piston, a 
side blow so pronounced that it causes a shaking of the sand, 
which is very detrimental to its packing and tends to loosen 
rather than to quickly and properly ram the mould. 

In years past, considerable was said regarding the merits of 
the bottom or center-strike machine, as compared with the top- 
strike machine, in which a large area of the table contacts with 
the base of the machine. Both styles of machines are producing 
moulds satisfactorily. While much can be said as to the merits 
of the two different types of machines, nevertheless these points 
are largely a matter of individual choice and preference, based 
upon the conclusions arrived at after becoming familiar with the 
results obtained from each of the different types. It should be 
pointed out, however, that the center-strike machine is one that 
produces a sudden reversal of the action of the falling parts, by 
the contacting with the anvil of a single surface of a small and 
yet sufficient area, and without an additional side motion to the 
moving parts ; therefore, the sudden reversal of the machine, 
with the absence of a side motion, has a decided advantage in 
the rapid packing of the sand. The top-strike machine, which is 
usually made with a short piston and cylinder, because of the ex- 
cessive strains caused by uneven loading on the table, produces 
rapid wear at the top of the cylinder and piston, which permits 
one side of the table to be in advance of the other side; the 
lower side of the table contacting first with the anvil produces a 
slap-like motion of the table, which, of course, sets up a shaking 
action in the packing sand, resulting in its requiring a longer 
time in which to completely ram the mould. 

In order to produce an economical operation by the con- 
sumption of the smallest amount of air, it is well to examine 
critically the many different styles of Plain Jolt-Moulding Ma- 
chines on the market. It is essential, in order to conserve the 
compressed air, that there be some means of controlling: the 



Plain Jolt-Moulding Machines 75 

amount used, and also to shut off the inlet port of the machine 
during the exhaust stroke. If the air inlet is permitted to remain 
open during- the exhaust stroke, a large amount of air is use- 
lessly consumed by its blowing through the machine and into 
the exhaust. 

While the jolt-ramming of a mould is a comparatively simple 
operation, yet considerable difficulty, in years past, has been en- 
countered in the ramming of the moulds required in foundries 
producing castings from various metals. 

The stroke required on Jolt-Moulding Machines that will 
economically and properly pack the sand of a steel casting mould, 
varies considerably from the stroke that is required to produce 
the mould into which is to be poured iron, brass or aluminum. 
In addition to the varying degree of hardness required in the 
mould, there are the elements produced by the use of the different 
grades of sand that are required in making the mould. To meet 
these varying conditions, it is well to have a machine the stroke 
of which can be adjusted to suit the requirements. The stroke, 
however, when once set for a particular foundry, rarely, if ever, 
requires further adjustment. 

The adjustable feature of the stroke, which, of course, is 
obtained by the adjusting of the valve on the machine, is, many 
times, a decided advantage when difficult copes are to be made, 
which in many instances require a long stroke with a sharp, 
quick blow, while in the majority of moulds a shorter stroke, with 
lesser blow, will accomplish the results in the same time and with- 
out the same amount of detrimental action to the machine and 
pattern equipment. 

In the early years of moulding machine operation, there ex- 
isted in the minds of foundrymen the feeling that the machine, 
when once installed in the foundry, should operate and give 
entire satisfaction without being cared for by a competent me- 
chanic. They did not realize the importance of keeping the 
machine properly oiled and free from sand obstruction. There 
should be in every foundry operating moulding machines a 
mechanic with sufficient mechanical intelligence to properly 
inspect and keep the machine in proper working condition. 



76 Foundry Moulding Machines and Pattern Equipment 

The pattern equipment, flask, etc., is another important item 
that has not been given the proper amount of consideration. 
Experience has thoroughly demonstrated that in order to secure 
the best results, proper attention must be given to equipping the 
machine with patterns, flasks, bottom boards, etc. In equipping 
the machine with patterns, exceptional care should be exercised 
to firmly secure the pattern to the pattern-plate, and patterns 
having a large flat surface should be thoroughly and strongly 
supported from the bottom in order to remove the possibility of 
a springing action taking place in the pattern when the mould 
is being rammed. If the pattern is not properly supported and 
a springing action takes place, the mould produced will be full of 
cracks, and if a cope, will drop out when the flask is being 
handled. 

The flasks also should be examined to see that they are rigid 
and of sufficient strength to prevent a springing action. The best 
results have been produced by the flasks that are cast solid in 
one piece. This is especially important when designing the cope 
half of the flask, and yet in some instances it is. difficult to cast 
integral the flask and the proper bars for supporting the sand. 
If it is found necessary to make use of a separate bar, it should 
be secured to the flask by means of rivets, or tightly fitted bolts, 
as a loose bar will prevent the making of a satisfactorily rammed 
mould. 

The above description of the equipment necessary in jolt- 
ramming applies not only to this particular chapter, but to all 
machines which make use of the jolt- ramming principle. 

The working action of the Jolt-Moulding Machine is such 
as to cause a vibration throughout its different parts. This vibra- 
tion, of course, becomes exaggerated when the machine is made 
up of many different castings. It has been exceedingly difiV 
cult to bolt together the different parts of a machine in a 
manner that will withstand the severe vibration produced in the 
bolted members. Where bolts are used, it has been found that 
the best type of lock washers are not sufficiently strong and rigid 
to hold the parts in place and, therefore, if bolts are a necessity, 
a method should be used that will absolutely prevent the loosen- 



Plain Jolt-Moulding Machines 77 

ing of the bolt ; for, if only a few bolts loosen, and the remaining 
bolts remain tight, an exceptional strain is produced on those that 
are holding, thereby causing a breakage of the casting or of the 
bolts. 

Modern requirement is rapidly demanding a machine de- 
signed with as few parts as possible, eliminating the bolted 
construction, and in its place a design that will withstand the 
severe vibration caused by the jolting action. 

Since the action of the Jolt Machine in operation is severe 
and very much like the same action as is used in breaking up 
scrap iron for the cupola, it is obvious that a machine that will 
withstand the repeated blows of jolt-ramming should be of a 
massive and heavy construction with as much of the blow as 
is possible prevented from reaching the different parts. 

The castings shown on the following pages were made on 
a Plain Jolt-Moulding Machine. The increased production of 
the Plain Jolt-Moulding Machine over hand moulding justifies 
its installation. Nevertheless, where there is available a Roll- 
Over Jolt-Moulding Machine, a still greater saving can be pro- 
duced, provided there are several castings to be made from the 
pattern. It has been demonstrated that the Roll-Over Machine 
can be used advantageously for a day's production of 96 moulds 
made from 16 different patterns. 



Foundry Moulding Machines and Pattern Equipment 




Fig. 67. Generator End Frame made on a 54"x66" Plain 

Jolt-Moulding Machine. 

The cope and the drag half of the mould are both made on this machine. 



:; 



Weiii: :; 






- f ^ 




J, 




F:i :; 





PRODUCTION 






lfei:-i rf I : 




-- ;\ 


I=5=« 


With: _: Virilize 


: 






u : a— : - : :: Plan foil 
Drag— f-^ :::: J: - "it 


;;;;;;; : g 




::•: ■■■ 



------- .- t: :::::_—; IIli-i^t - : zl : 



Foundry Moulding Machines and Pattern Equipment 




Fig. 69 
Steel Casting Press Cylinder. Weight 610 pounds. 

Production based on making both the cope and the drag half of the 
mould on the same machine. 



PRODUCTION 

No. Quan. % 

Method of Moulding Men Hours Moulds Increase 

Without Machine 4 9 2 

Cope — 54"x66" Plain Jolt 

Drag— 54" x 66" Plain Jolt 4 9 5 150% 

A Roll-Over Jolt-Moulding Machine would give an increase in production of from 
300 to 400%. 



Plain Jolt-Moulding Machines 





Fig. 70 
Railway Truck Bolster — Steel Casting. Weight 430 pounds. 



Production based on making both the cope and the drag half of the 
mould on the same machine. 



PRODUCTION 

No. 
Men 

5 

'.'.'.'.'.'. 5 

A Roll-Over Jolt-Moulding Machine would give an increase in production of from 
300 to 400%. 



Method of Moulding 


No. 
Men 


Hours 


Quan. 

Moulds 


% 

Increase 


Without Machine 


5 


9 


12 




Cope— 42" x 97" Plain Jolt 

Drag-^12" x 97" Plain Jolt 


;; 5 


9 


30 


150% 



82 



Foundry Moulding Machines and Pattern Equipment 



■■ (VJ 
□ 10 
CO I-n 



78 

m (£81 



W2 




Standard 
Open Hean 
Cast Steel Charging Box 



TheWellman-Seaver-Morgan Co., Clevelan4, 



Fig. 71 
Weight of casting 1210 pounds 



Production based on making both the cope and the drag half of the 
mould on the same machine. 

PRODUCTION 

No. Quan. % 

Method of Moulding Men Hours Moulds Increase 

Without Machine ~ 4 9 2 

Cope— 54" x 66" Plain Jolt 

Drag— 54" x 66" Plain Jolt 4 9 6 200% 

A Roll-Over Jolt-Moulding Machine would give an increase in production of from 
300 to 400%. 



PJain Jolt-Moulding Machines 



S3 



Base and Cylinder Cast Integral. 



Weight 1700 pounds. 




£=0^3 



Fig. 72 



Production based on making both the cope and the drag half of the 
mould on the same machine. 

PRODUCTION 

No. Quan. % 
Method of Moulding Men Ho urs Moulds Increase 

Without Machine 4 9 2 

Cope— 54" x 66" Plain Jolt 

Drag— 54" x 66" Plain Jolt 4 9 4 100% 

A Roll-Over Jolt-Moulding Machine would give an increase in production of from 
500 to 600%. 



84 



Foundry Moulding Machines and Pattern Equipment 


















( J 


!> 




\ 






f 


"* 


1 








33" 








« 




» 


t 








I 






y 








=e 


3= 







Side Frame Casting. 



Weight 




pounds. 



Production based on making both the cope and the drag half of the 
mould on the same machine. 



PRODUCTION 

^Nol Quan. % 

Method of Moulding Men Hours Moulds Increase 

Without Machine 4 9 2 

Cope — 54" x 66" Plain Jolt 

Dra g— 54" x66" Plain Jolt ._ __4_ 9 4 100% 

A Roll-Cher Jolt-Moulding Machine wouid give an increase in production of from 
400 to 500%. 



Plain Jolt-Moulding Machines 



85 




Fig. 74 
Truck Center Casting for Locomotive Crane. Weight of casting 1680 pounds. 



Production based on making both the cope and the drag half of the 
mould on the same machine. 

PRODUCTION 

No] 
Men 

3 

'.'.'.'.'.'. 3 

A Roll-Over Jolt-Moulding Machine would give an increase in production of from 
400 to 500%. 



Method of Moulding 


No. 
Men 


Hours 


Quan. 
Moulds 


% 

Increase 


Without Machine 


3 


9 


1 




Cope — 54"x66" Plain Jolt 

Drag— 54" x 66" Plain Jolt 


'.'. 3 


9 


2 


100% 



86 



Foundry Moulding Machines and Pattern Equipment 




Fig. 75. Large and Difficult Table Casting. Weight 1500 pounds 



Production based on making both the cope and the drag half of the 
mould on the same machine. 

PRODUCTION 

No. Quan. % 

Method of Moulding Men Hours Moulds Increase 

Without Machine ' 3 9 1 

Cope — 54"x66" Plain Jolt 

Drag— 54" x 66" Plain Jolt 3 9 2 100% 

A Roll-Over Jolt-Moulding Machine would give an increase in production of from 
500 to 600%. 



Plain Jolt-Moulding Machines 



87 




Fig. 76. A floor of Generator End Frame Moulds made on the Plain Jolt 

Machine shown in the foreground, at the plant of 

THE WESTINGHOUSE ELECTRIC & MFG. CO. 

Cleveland, Ohio, U. S. A. 



Foundry Moulding Machines and Pattern Equipment 




CHAPTER VII 
Air-Operated Squeezer Moulding Machine. 

Primarily the air-operated squeezer type of moulding ma- 
chine was designed to replace the old laborious hand method of 
bench-moulding for light work. The question of producing, 
rapidly and economically, large numbers of small castings from 
one pattern, is one that cannot be lightly treated; this fact is 
evident from the varied and interesting devices designed to 
facilitate this class of foundry work. The first development in 
the art produced a single pattern with its match of green sand; 
next on a single gate, then the improving of the green sand 
match by substitution of fire-clay or oil-sand for the delicate 
green sand ; further development produced a match board similar 
to the modern match plate. Then various plates were first used 
for hand-ramming on the bench, but soon a squeezer type of 
moulding machine, crude in design and hand-operated, came into 
favor and was extensively used throughout the United States of 
America. 

The original type of air-operated squeezer was designed 
purely and simply a mould-squeezing machine, as its name im- 
plies, and this type is still doing efficient and rapid work in its 
own particular line. With the plain squeezer type of machine 
the most common and extensively used form of pattern is that, 
of the match-plate type, although the vibrator-frame and oil-sand 
match are also frequently used. 

Combination Jolt Squeezer 

Later it was found that a great many patterns belonged in 
the squeezer class of work, as the weight of the casting was 
such as could be produced by squeezer-moulding, but the depth 
of the mould prevented the use of this type of machine, as the 
squeezing failed to pack the sand properly at the bottom of the 
pattern and next to the match plate ; to meet this difficulty a 
machine was designed that embodies the principles of both the 
squeezer and the jolt machines. This machine is in appearance 



90 Foundry Moulding Machines and Pattern Equipment 

the same as a standard air-operated squeezer, but is called a 
Jolt-Squeezer Moulding Machine. It has mounted within the 
large squeezer piston a small jolt cylinder in which operates 
the jolt-piston carrying the table of the machine, usually cast 
integral with the piston. No changes are required to use either 
feature of this dual machine, hence a deep mould may be jolted 
to pack a deep recess, by a slight pressure of the knee against 
an air inlet valve. A few jolts of the mould settles and begins 
the packing of the sand in the recess of the pattern and the corners 
of the flask, after which the mould is squeezed in the usual manner, 
packing the remainder of the sand in the flask. This feature of 
double utility is also an effective means of preventing what is 

Of 



1U, ) — i y 

... __ .... 




Fig. 78. Air-Operated Squeezer Moulding Machine with 
Mould in Position for Squeezing. 

known as "ram-off," an annoyance caused by the sand, after being 
tucked against the side of the pattern or into a depression, being 
pushed away again by the squeezing action of the Plain Squeezer 
Machine. These machines are used not only in the standard 
design, but also with other special attachments, for example, a 
stripping or pattern drawing device, and when so equipped is 
commonly known as a Split Pattern Machine. These machines 
are used for a heavier class of work, such as flywheels for small 
gas engines, valve and pipe fittings, gears, etc. They are usually 
operated in pairs ; the drag pattern mounted on one machine, and 



Air-Operated Squeezer Moulding Machine 91 

the cope pattern on the other. The addition of this device does 
not in any way interfere with the usual operation of the machine 
as a standard squeezer. It is also used extensively for such 
patterns as require stooling. 

The standard types of Air-Operated Squeezer Moulding 
Machines are usually mounted on wheels. The advantage in the 
use of this construction is that, if desired, the machine can be 
moved along the side of the sand heap on the working floor — 
or can be permanently located, and the sand piled in a heap 
beside it. Even though the machine is permanently located, there 
is still a decided advantage in the use of the wheels, as it allows 
the moulder to shovel the sand which falls underneath the ma- 
chine while in operation, without his shovel coming in contact 
with the lower part or the body of the machine. 




Fig. 79. Air-Operated Squeezer Moulding Machine with Pattern 
Drawn from the Mould. 

Sand Straddler Squeezer 
Another style of air-operated squeezer is that known as the 
Sand Straddler, mounted on wheels having a wide span. This 
machine is designed to straddle or span the sand heap, the sand 
being piled in long rows, but shorter than the length of the 
moulding floor, to permit placing the first moulds and allow work- 
ing place. As the floor is filled with moulds the machine is 
pushed ahead, the sand being taken from beneath the machine. 



92 



Foundry Moulding Machines and Pattern Equipment 



Description 

In air-operated squeezing- machines of any size or type, 
should be found incorporated the following - principles : All work- 
ing parts should be fully enclosed or shielded against sand and 
grit ; the place for moulding sand is either in the mould or on the 
floor, hence the contours of the exposed members of the machine, 
as far as possible, should be of the inverted "V" design so as to 
shed the falling sand; simplicity of operation is essential to its 
proper working under the conditions usually existing in the 
foundries ; pistons should be provided with cast-iron piston rings 
and proper oiling facilities ; the strain rods carrying the pressure 
head should be adjustable for height to meet the conditions exist- 
ing due to varying height of flask used; the pressure head and 
strain rods should be counterbalanced ; operating valve should be 
in convenient location at right of operator and below the working 
position of the table; this operating valve should be automatically 
locked except when pressure head is in squeezing position ; there 
should be a release pop valve releasing pressure in the cylinder 




Fig. 80. An Air-Operated Jolt-Squeezer Moulding Machine, 
when mould has been squeezed to a predetermined density, pres- 
sure gauge, blow valve, riddle bracket, and a shelf for holding 
the cope half of the mould while drawing pattern from the drag 
half which is still left on the table of the machine. These fea- 
tures make a self-contained and independent unit. 

OPERATION 

A description of the operation of the squeezer 
be found in Chapter VIII, Pages 109 and 112. 



machine may 



----- 




94 Foundry Moulding Machines and Pattern Equipment 




Air-Operated Squeezer Moulding Machine 



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96 Foundry Moulding Machines and Pattern Equipment 




CHAPTER VIII 

Pattern Equipment. 

Patterns are divided into two general classes — wood and 
metal. The material used in the making of a metal pattern may- 
be either brass, aluminum, white metal or iron, depending, of 
course, upon the size and whether or not the pattern in mould- 
ing is to be handled or fastened to the table of the machine. 
Metal patterns are made from master patterns, which for ma- 
chine mounting should be provided with the necessary ribs rp 
reinforce any weak portion of the pattern. It is well also, where 
possible, to provide suitable lugs or bosses (preferably inside 
the profile of the pattern) for fastening the pattern to the pattern 
plate, altho in some instances the pattern and pattern-plate are 
cast integral. The necessity for rigidity of construction cannot 
be too strongly emphasized in the making and mounting of pat- 
terns that are to be used for jolt machine-moulding, as the pattern 
that is so made as to permit a springlike action to take place 
while the machine is being jolted, will cause a vibration that will 
prove very detrimental to the proper packing of the sand, and if 
such a pattern is used, the mould will be full of cracks or other 
imperfections. Therefore, considerable stress must be laid upon 
the importance of properly reinforcing the flat surfaces of the 
pattern in such a manner as to prevent vibration. 

The pattern should not be designed until the style of the 
moulding machine for producing the mould has been determined, 
after which consideration should be given to the proper size of 
flask. In determining the size of flask that should be used in con- 
nection with the moulding machine, it is well to keep in mind the 
fact that a machine-rammed mould, made in a suitable flask, does 
not require as large an amount of sand between the pattern and 
the flask as has been the common practice in the foundries mak- 
ing use of a more fragile type of flask or those making use of 
the ordinary wood flask. 

It is well to point out the necessity of considering the ad- 
visability of producing the mould in a rectangular flask, i. e., 



Foundry Moulding Machines and Pattern Equipment 



whether or not the quantity of castings to be made from the 
pattern is such as would warrant the making of a flask of a 
special shape, following the outline of the pattern, commonly 
known as "cut" flasks. 

Metal Patterns and Pattern Plates 
As has been pointed out, when mounting patterns which 
are to be used on jolt-moulding machines, extreme care should 
be taken to see that the pattern is thoroughly reinforced and 
free from all possibility of a springing action taking place in 
the pattern itself while the mould is being jolted. Patterns for 
use on this type of machine, from which a large quantity of 




Fig. 85 



Fig. 86 





•'' 






., 


/ 


00^^ 


* , 



Fig. 87 

castings is to be produced, are usually made of metal and 
mounted on iron plates. The thickness of the plates should not 
be decided until after determining the height they should be 
made, in order to conform to the moulding machine on which 
they are to be used. Where it is possible, they should be made 
deep and hollowed out in the back, also reinforced by ribs run- 
ning in both directions, and, if the plate can be made of suf- 
ficient height, a hole should be provided on the sides, suitable 



Pattern Equipment 



99 



for attaching clamps for holding - the bottom board and flask to 
the plate, while the mould is being - rolled over. 

Figures 85, 86, and 87 clearly illustrate the high state of 
attainment in the art of pattern-making. The patterns are of a 
design requiring the highest grade of workmanship, in order to 
produce the profiles which will match and maintain the uniformity 
of section that is required in this particular type of casting — the 
section in many cases being not more than T V' m thickness. 

In Figure 107 is shown the cope and drag halves of a metal 
pattern mounted side by side upon the table of a Roll-Over Jolt- 
Moulding Machine. A careful study of this view will convince 
the reader that this style of operation is economical where the 
pattern is of a length to permit its being used in this manner. 




Fig. 88 Fig. 

In the view here shown it will be noted that sufficient blocking 
has been provided below the pattern-plates to make the top of 




Fig. 90 



Fig. 91 



both cope and drag halves of the flask the same distance from the 
table of the machine. 



100 



Foundry Moulding Machines and Pattern Equipment 



Wood Patterns and Pattern Plates 

Machine-moulding is so thoroughly a part of the automobile 
industry that very little comment is necessary upon the manner 




Fig. 92 

in which patterns are made, and the views which show automo- 
bile castings are used only for the information of those other 
foundrymen who are not familiar with the progress that has been 
made in the automobile foundries. Therefore, in order to show 
the use of the jolt-moulding machine in plants other than the 
specialty foundries, and the gain to be made from their universal 
use in foundries, illustrations are shown and a full descrip- 
tion given of the method of making and mounting wood patterns 
upon wood plates; also the practice in use in some foundries 




Fig. 93 



Pattern Equipment 101 



where a universal plate is used and patterns of all shapes and 
sizes are mounted on the plate, in order to fill the standard size 
flask provided for the standard pattern-plates that have been 
adopted. 

Figures 88, 89, 90 and 91 show several patterns mounted on 
wooden plates. They also show the condition of the patterns 
after hundreds of casting's have been made. These patterns were 
used on a medium size Roll-Over Jolt-Moulding- Machine. 

The group of patterns shown in Figures 92 and 93 is illustra- 
tive of the best method of making patterns for use on jolt-mould- 
ing machines. These patterns were originally laid out and made 
for jolt-moulding; the patterns and plates have been constructed 
together (the patterns being built solidly into the plate) making 
both the plate and the pattern more durable than when made 
separately and fastened together by means of bolts or screws. 
It has been fully demonstrated by cost records that a pattern 
of this description can be made at a cost not exceeding that of 
making the same pattern for floor moulding. 

Jobbing foundries are confronted with the necessity of mak- 
ing use of patterns which the customer sends them and which 
are usually made for floor ramming. If the foundryman desires 
to make the moulds on a moulding machine, it is necessary to 
alter the pattern, or at least to provide plates upon which he can 
mount the pattern. This situation has been met in some foun- 
dries by the use of a master pattern-plate, made from either 
steel or wood ; if made of wood, they are usually edged with 
metal cleats upon which the flask is to rest, and which also pro- 
tects the wooden plate. These master plates are provided with 
center lines which make it a simple matter to align the patterns 
that are placed thereon. 

From the views shown in Figures 94, 95, 96 and 97 it will 
be seen that there can be mounted on the plates many different 
shapes, styles and sizes of patterns, the object being to always 
fill the plate with patterns in order to make use of all the avail- 
able space in the flask. The views of the plates shown in Figures 
96 and 97 especially emphasize this possibility as there are 
several different styles of pattern poured from one gate. The pat- 



102 



Foundry Moulding Machines and Pattern Equipment 



terns shown in these figures, with the exception of the gear, are 
so-called "flat back" patterns, requiring no part of the pattern in 
the cope. By referring to Figure 97 it will be noted that the 
cope-plate, standing alongside the drag-plate, is provided with a 
depression that aligns with the gear shown on the drag-plate, this 




Fig. 94 Fig. 95 

depression produces the proper shaped cope half of the mould for 
the gear. The particular plates shown in these four figures were 
made to be used in connection with a Roll-Over Jolt-Moulding 
Machine. 

Comparison of Machine and Floor Patterns 
In order to more clearly bring before the reader the possi- 
bility of the great saving to be made, by originally making the 
patterns to be used for machine moulding, there are shown in 




Fig. 96 Fig. 97 

the following views, the casting to be produced, the pattern as 
it was made for use on the moulding floor, and also as it was 



Pattern Equipment 



103 



later mounted to be used on either the Plain-Jolt or Roll-Over 
Jolt-Moulding Machine. 

Figure 98 and 99 (combined) shows a casting difficult to 
make, and the manner in which the pattern was made for hand- 
ramming on the moulding floor. Observe the "stop-off" piece 
used in order to hold the shape of the pattern while the mould 
was being rammed, which was difficult to do regardless of the 
stiffening member. 

Fig. 100 shows the manner in which a new pattern was later 
mounted on pattern-plates for use on jolt-moulding machines. 
The difficulty experienced in the producing of a casting straight 
and true to pattern was entirely eliminated by the use of the 
pattern-plates. 

Figs. 101 and 103 show large and difficult castings. 




Fig 98 



Fig. 99 



Fig. 100 



Figs. 102 and 104 show patterns as they were originally made 
for use, either on the floor or on jolt-moulding machines. How- 
ever, it was only possible to make the drag half of the mould 
on the machine when using the patterns without being mounted 
on pattern-plates. This was accomplished by placing the patterns 
flat on the table of the machine and after jolt-ramming the drag 
half, the flask and pattern were rolled over and placed on the 
foundry floor, and the cope half of the pattern rammed by hand 
in the usual way. 

Fig. 105 is still another view, which again emphasizes the 
advantage to be gained by mounting the patterns on pattern- 
plates, especially fragile patterns. 

In the early days of machine-moulding there was developed 



104 



Foundry Moulding Machines and Pattern Equipment 



a method of mounting patterns known as "shell patterns." Such 
patterns when mounted for machine use were usually made for 
the production of castings in large quantities, the cope and the 
drag being mounted on separate machines — usually the drag on 
a roll-over type of machine, and the cope on a stripping-plate 




Fig. 101 

machine. The method devised was such as to make use of the 
shell pattern for either the cope or drag-plate. 

The views shown in Fig. 106 are of the cope and drag 
patterns mounted on a stripping-plate and roll-over machine 
respectively. The pattern here shown is a jacket of a hot 
water gas heater with the shell varying in thickness from y§" to 
i 3 /'- The shell pattern was used for the cope-plate, while a 
white metal match was made from the shell pattern, and used 
for the drag-plate. Foundries producing stove castings generally 
make use of this method of pattern-mounting, the details of 
which are well known to trie industry. 

Match Plates and Vibrator Frames 
There are several different methods in use for the making 
and mounting of patterns to be used in connection with air- 
operated squeezer machines. 




Fig. 102 



Pattern Equipment 



105 



It is, of course, necessary, when producing- match-plate pat- 
terns, to first provide a set of gate patterns, from which is made 
the match-plate, provided it is to be of cast material, or, if the 




Fig. 103 Fig. 104 

parting lines of the patterns are uniform, it is possible to use a 
standard flat plate of either steel or aluminum, in which case the 
individual patterns may be machined separately and properly 
mounted on both sides of the plate. 

If the match-plate is to 
be cast, either because this 
method is more economical, 
or because the match-plate has 
an uneven parting line, the 
method of procedure is as 
follows : 

A master wood pattern is 
prepared of the desired cast- 
ing, making allowance for the 
shrinking of the match-plate 
material in addition to the 
shrinking of the metal from 
which the casting is to be 
made. Precaution should be 
used, when making this pat- 
tern, to see that the pattern 
is perfectly smooth and free 
from back draft. A mould 
is made from this pattern in 

Fig. 105 




I ff ::T -"-■- ■ ■■:-.--■ ; i ;:j fr 




106 



Foundry Moulding Machines and Pattern Equipment 



the usual way, using a flask sufficiently large to contain the size of 
the plate desired. The mould is then parted and strips of wood 
the thickness desired for the plate, about %"', are laid on the 
drag; the outer edges of these strips representing the extreme 
edges of the finished plate. When it is desired to have the guide 
pin ears cast integral with the plate, the strips of wood represent- 




Fig. 106 

ing the ends of the plate must have their outer edges shaped to 
conform to that of the desired ear. A place should likewise be 
provided for attaching the vibrator. 

A new parting must be built around and outside of the 
strips of wood, to the same height as the uppper surface of the 
strips, in order to separate the mould after the wood strips have 
been removed. The mould is then closed and poured in the 
usual manner. 

Match-plates of this type are cast from either brass, white 
metal or aluminum, and if proper 
care has been exercised in mak- 
ing the mould, they require very 
little finishing or scraping; a 
brushing with a wire scratch 
brush and the removal of any 
Anns is usually all the finish re- 
quired. After the flask pin guides 
and vibrator have been attached 
to it, the plate is ready for use. Fig. 107 




Pattern Equipment 



107 



Match-plates of this description are shown in Figures 108 
and 109, together with the moulds ready for closing and pouring. 

Another variety of match-plate, easily constructed when the 
parting line of the mould is a flat surface, is made by attaching 
the halves of the pattern to opposite sides of a metal plate. A 
very satisfactory method of doing this is to procure a metal 




Fig. 108. Upper left— Cope-Mould; right— Cope side of plate. 
Lower left — Drag side of plate; right — drag mould. 

plate of steel or aluminum the size of the desired match-plate, 
not overlooking the ears for the guide pins. The halves of each 
pattern, which is of the split type and made of metal, are then 
clamped together, and two or more dowel pin holes drilled thru 
both parts. The drag portion of the pattern is located on the 
plate, together with the runner and gates ; and, using the dowel 
pin holes in the pattern as guides, the same size holes are drilled 
thru the plate. The dowel pins can then be driven thru the drag 
pattern, the plate and the cope pattern. The halves of the pattern 
are now accurately aligned on opposite sides of the plate and 
may be secured to it by means of screws or pins. The match- 



108 



Foundry Moulding Machines and Pattern Equipment 



plate should then be provided with the proper flask pin guides, 
after which it is ready for the foundry. Figure 110 shows a 
pattern well suited to this form of match-plate. 

The vibrator frame provides a satisfactory means of using 
solid metal patterns, or a gate of patterns, without a great amount 
of work being connected therewith. The vibrator frame and 
patterns are used in connection with a hard match. The frame 




Fig. 109. Upper left — Cope mould; right — Cope side of plate. 
Lower left — Drag side of plate; right — drag mould. 

is made of either aluminum or cast iron, about Y%" thick by 1" 
in width, the length and width of the frame being the same as 
the outside dimension of the flask with which the vibrator frame 
is to be used. The guide pin ears are cast integral with the 
frame, and then this frame is placed over the pattern, which is 
secured by means of brass metal strips about y§" in thickness, 
and extending along the parting line of the mould. This strip 
of metal is securely fastened to the pattern or gate of patterns 
and vibrator frame, as shown in Fig. 11. The hard match is 
made in the same manner in which a regular mould is made. 



Pattern Equipment 



109 



The material used in making the hard match varies, although 
the following formula has been found to give satisfaction: To 
eight parts by weight of boiled linseed oil, add by weight, one 
part of yellow oxide of lead. A sufficient amount of the mixture 
is added to new moulding sand (which should be baked to insure 
it being thoroughly dry) to 
make it the consistency of 
well tempered moulding sand. 
The vibrator frame is placed 
in the flask and the drag and 
cope rammed in green sand. 
The cope is then removed and 
replaced with a wood frame, 
previously prepared for con- 
taining the match preparation. 
The surface of the drag and 
the pattern are then dusted 
with suitable parting material, 
and a new cope rammed up in 
the match frame, using the 
match material. The surface 
of the match is then made 
even with the frame, and a 
bottom board secured in place 

with screws. The mould is Fig. 110 

next rolled over and the green-sand drag removed. The pattern 
can then be drawn and any portion of the match that has been 
injured by the drawing of the pattern can be repaired. The 
match should then be set aside in a warm place for about twelve 
hours and allowed to become hard and dry ; shellac may be 
applied for the purpose of further water-proofing. A gate of 
patterns, suspended in a vibrator frame, together with the hard 
match and a mould made from the patterns, are shown in 
Fig. 111. 

The gated pattern and hard match, shown in Fig. 112, are 
prepared for use by the simple process of making a hard match 
for the cope of the pattern, which is used in the same manner as 
the vibrator frame, except that no vibrator is used, the pattern 
being rapped thru the sprue as in bench moulding. 




110 



Foundry Moulding Machines and Pattern Equipment 



Using Match Plates and Vibrator Frames 

To use a match-plate on an air-squeezer moulding machine 
requires the match-plate, a flask-parting compound, a tubular 
sprue cutter, a quantity of bottom boards, a cope board and the 
vibrator. The cope half of flask is placed on the table of the 
machine, and upon this the match-plate — the cope side being 




Fig. 111. Upper left — drag mould; right — cope mould. Lower left — 
hard sand match; right — pattern mounted in vibrator frame. 

turned downward. The parting substance is then dusted over 
the drag side of the match-plate, and sufficient sand riddled into 
the flask to completely cover the pattern. Sand is then taken 
from the sand heap to fill the flask, and the flask "struck off," 
using the bottom board for a "strike," and the bottom board 
placed in position on the mould. The bottom board must be 
about J /s" smaller all around than the inside of the flask. The 
mould must now be rolled over and the operation repeated to 
fill the cope flask. Instead of a bottom board, however, a cope 
board is used, which is similar to the bottom board, but has a 



Pattern Equipment 



111 



button secured to the face of it, serving to locate the position of 
the sprue. The pressure head is then drawn forward, the operat- 
ing - valve handle pressed down and held until the relief or "pop" 
valve operates. The squeezing is then complete. The pressure 
head is then pushed back and the cope board removed. The sprue 
is cut by means of a brass tube sprue cutter, at the point indicated 
by the impression of the button secured to the cope board. The 



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Fig. 112. Upper left — hard sand match; right — gated pattern. 
Lower left — drag mould; right — cope mould. 

vibrator is then started by the pressure of the knee on an air 
inlet valve, and the cope half drawn off and set on the shelf at 
the left side of the machine. The vibrator is again applied and 
the match-plate of patterns withdrawn from the drag half of 
the mould; the match-plate is then placed on the pressure head, 
and allowed to lean against the handle, which is covered with 
rubber in order to prevent marring of the patterns. 

The vibrator frame type of pattern is moulded in a similar 
manner. The pattern, in its hard match, is placed on the table 
of the machine, the drag flask set in place, and the sand riddled 



112 Foundry Moulding Machines and Pattern Equipment 

into the flask ; it is then filled and struck off. The bottom 
board is then placed, and the mould is rolled over. The match- 
is then removed and replaced by the cope flask. The pattern 
and the sand in the drag flask are dusted with parting com- 
pound, and the cope filled with sand, in the same manner as 
the drag. The cope board is placed on the top ; the pressure 
head drawn into position, and the squeezing operation performed 
as before described. The cope board is then removed and the 
sprue cut. The pattern is vibrated again and drawn from the 
drag. The impressions of the strips holding the pattern in the 

frame must be stopped off with 
sand, after which the mould is 
closed and placed on the pour- 
ing floor. 

The ordinary gated pattern 
is handled in the same manner 
as the vibrator frame, except — 
there being no means of attach- 
ing a vibrator to the pattern — it 
is rapped thru the sprue, as in 
ordinary bench moulding, and a 
draw spike used for lifting the 
Fig. 113 pattern from the drag. 

Stripping Plate Patterns with Stools 

There is also a system of squeezer-moulding used exten- 
sively among pipe fitters, and makers of other similar castings, 
which makes use of a pair of machines operating on one pattern. 
Such machines are called "split-pattern" squeezer-moulding ma- 
chines. The only difference between this method and the match- 
plate method (which is used on the regular squeezer-moulding 
machine) is that two plates are used instead of one, i. e., the 
cope part of the pattern is mounted on one plate and the drag 
part of the pattern on another plate, the patterns of the two 
plates being so mounted as to properly align after the two halves 
of the mould have been set together. 

The "split-pattern" type of squeezer-moulding machine is 




Pattern Equipment 



113 



also convenient for moulding that type of squeezer work requir- 
ing stools to aid in drawing the pattern from certain portions of 
the mould. 




Fig. 114 

In order to satisfactorily produce moulds by the jolt-ram- 
ming squeezer method — from patterns having pockets or de- 
pressions, and which likewise require a suspended body or bodies 
of sand to be held securely in place, while the pattern is being 
withdrawn from the sand — it is necessary to stool the pockets 
or depressions of the pattern, i. e., the pendant sand is supported 




Fig. 115 

while the flask with the mould is withdrawn from the pattern. 
This will be explained more fully in the following detailed de- 
scription. 



114 Foundry Moulding Machines and Pattern Equipment 

To illustrate this method of moulding, Figure 113 shows a 
jolt-squeeze and stripping-plate moulding machine, which is 
especially adapted to this particular type of work. 

Figure 114 is a cross-section drawing of the drag of an auto- 
mobile flywheel pattern, while Figure 115 shows a cross section 
of the cope pattern. It is obvious that the sand between the 
rim and the hub of the drag half of the mould, also the body of 
hanging sand in the cope, will require supports when stripping 
the pattern from the mould. The drag and cope patterns consist 
of sub-plates A, which are bolted and doweled to the jolt-table. 
Stripping-plate B, by means of which the flask is lifted or drawn 
from the pattern, and which rests on the sub-plate A, is elevated 
by means of pins at each end of the sub-plate, as well as the rim 
of the flywheel C; as the same principle is applied to both the 
cope and the drag moulds, it is necessary to describe only the 
drag part of the pattern. The sub-plate has a central projection 
extending upward and forming the hub of the flywheel, and the 
core print of the hub core. 

The rim of the flywheel pattern consists of a ring with a 
multiple number of downward extending lugs, by means of 
which it is securely fastened to the sub-plate A; each leg extend- 
ing thru the holes in the stripping-plate B. 

The hub and rim of the pattern should be cast integral with 
or bolted to the sub-plate, and remain stationary while the 
stripping-plate B is being lifted, thus stripping or drawing the 
mould from the hub and rim. The pendant part of the mould 
is supported by stripping-plate B during this operation. 

It will be noted that the stripping-plate lifts the flask and 
at the same time strips the hub of the pattern from around the 
center of the hub and the inside and the outside of the flywheel 
rim. 

To produce good moulds and consequently sound castings, 
it is not only necessary to be able to strip this type of pattern, 
but also to make sure that the sand is securely held in position 
by the stool plates, while the mould is being lifted from the 
stripping-plate. It is also necessary to provide a means to insure 
the sand being securely held while the mould is carried and 



Pattern Equipment 115 



placed on the pouring floor; this is accomplished by casting ribs 
on the flask, as shown by the dotted lines in Figures 114 and 115. 
The section of these ribs should be tapered, the point next to the 
pattern decreasing to a size about %" and as close to the pattern 
as will permit a uniform ramming of the sand over the entire 
surface of the patterns. The distance between these ribs and 
the pattern should not be more than J / 2 n '. It is important that 
the ribs referred to be substantial, so as to avoid vibration 
which would destroy the mould while being jolt-rammed. 



CHAPTER IX 
Machine Moulded Gores. 

The exceptional demand of the automobile industry for cast- 
ings, in addition to forcing the use of a method of moulding that 
was speedier than the method in use a few years ago, also made 
necessary a way in which to produce the tremendous quantities 
of dry-sand cores that were required for the production neces- 
sary to meet the demand. 

There are a number of different styles of moulding machines 
that are used to advantage in the core-room. There are also a 
number of the smaller cores that can be made by hand on the 
bench faster than when made on moulding machines. There- 
fore, it is the large, yet delicate and intricate core with which 
this chapter will deal. 

The subject of core-making is one of such magnitude that 
the little given in this chapter appears insignificant; it is with 
a keen realization of this fact that the author ventures to show 
and describe a few of the core-making operations, attempting 
only to create in the minds of those who are not familiar with 
the highly developted state of the art, a desire to know more 
of the possibilities awaiting the introduction of the moulding 
machine into the core-room. Therefore, with this explanation 
the reader is requested to refer to Figure 116, which illustrates 
several complicated cores that have been produced on the mould- 
ing machine. By careful study of the view, it will be seen that 
some of these cores are made in one piece, while others are views 
of several cores assembled together. 

Gauging- and Inspection of Dry Sand Cores 

Foundries producing high grade castings have adopted a 
rigid system of core-inspection by which the various individual 
cores are measured by gauges, having the allowable limits. 

In addition to the gauging and inspecting of the individual 
core, extreme accuracy is required in the setting, and there- 



118 Foundry Moulding Machines and Pattern Equipment 




Fig. 116 



fore, to insure the core being 
accurately set, there has been 
devised a system of assembly 
jigs in which the detail cores 
are made fast into the com- 
posite core assembly, and held 
firmly in place by pouring 
lead into the interlocking 
holes provided in the different 
detail cores. 




Fig. 117 



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Fig. 118 



Machine Moulded Cores 



119 




Fig. 119 



Assembling of 
Complicated Cores 

Assembly and Setting 
Jigs 

Figure 117 shows clearly 
the manner in which the core 
is assembled. The various 
cores after being assembled 
into one complete core and 
gauged for accuracy and then 
placed into the mould in the 
meet the requirements, as it 



ordinary manner, still failed to 
was found that sufficient accuracy could not be attained, be- 
cause of variation, due to core straining the core-print pockets, 
when being lowered into the mould. This condition was 
overcome by providing suitable core-setting jigs, as illustrated 
in Figures 118 and 119. Figure 118 shows in the background an 
assembly jig and in the foreground the assembled core attached 
to the setting jig. Figure 119 shows the manner in which the jig 
is used while lowering the core into the finished drag-mould. It 
will be seen from this view that the core-setting jig is guided 
to place by means of the flask pins. The style of casting which 

this mould will turn out is 
shown in the foreground. 

The cores illustrated in 
the previous views were made 
on the moulding machine illus- 





Fig. 120 



Fig. 121 



120 



Foundry Moulding Machines and Pattern Equipment 




trated in Figures 120 and 121. 
From Figure 120 it will be 
seen that the core has been 
rammed on the machine and 
then rolled over and the pat- 
terns and loose pieces drawn 
from, the main core-box. Fig- 
ure 121 shows the same core 
after it has been lifted to the 
side of the machine, the loose 
pieces withdrawn and the 
core-box partly rolled back in' 
Fig. 122 order that the complicated 

core-box may be seen to advantage. 

Dry-sand piston cores are produced at the rate of six per 
operation on the machine shown in Figure 123 ; while in Figure 
124 the producing of piston moulds is shown, using the green- 
sand core method instead of the dry-sand. 

Green Sand Cores 
Fig. 124 shows a mould for the making of grey iron 
castings for gas engine pis- 
tons. This is a good example 
of green sand cores, as they 
are made on a moulding ma- 
chine. The cores are formed 
integral with the drag portion 
of the mould in a metal core- 
box, so arranged as to pro- 
duce four cores at one cycle of 
operation. This core-box is of 
the split type, and is parted di- 
rectly through the centers of 
the cores. The wrist-pin 
bosses are secured to the in- 
side of the box on a center 

Fig. 123 




Machine Moulded Cores 



121 




line at a right angle to the 
parting line of the box. The 
top of the box forms a fiat 
surface of sufficient area to 
form the parting line of the 
mould. The members of the 
core-box are arranged to be 
separated in a horizontal 
Fig. 124 plane, by means of a lever 

located at the back of the box, so as not to interfere with the 
movements of the operator. Tongues are provided on the ends 
of the core-box members which slide in grooves in the upright 
ends of the frame. A bearing strip provided at the bottom of the 
box prevents the distortion of the box while being rammed. This 
core-box was mounted on a Roll-Over Moulding Machine and 
was used in the following manner: with the core-box set in the 
position shown in the illustration, the drag flask was placed on 
the core-box with the pins on the core-box properly engaging 
the holes in the flask ears. The core-box was then filled with 
riddled moulding sand and the sand tamped and packed on the 
lower side of the wrist-pin bosses, after which the flask was 
filled and rammed complete. The mould was then "struck off," 
the bottom board clamped in place, and the table carrying the 
core-box rolled over. The leveling bars were then brought up 
against the bottom board and 
the automatic leveling pins 
locked. The bottom board 
clamps were next released, 
after which the vibrator was 
started and the members of 
the core-box drawn apart by 
means of the lever provided 
for the purpose. The flask 
and cores were then lowered 
to clear the core-box and re- 
moved from the machine to 
the position shown in illustra- 
tion. Fig. 125 




122 



Foundry Moulding Machines and Pattern Equipment 




Tunnel Segment Cores 

The tunnel segment cast- 
ing', fully illustrated and de- 
scribed in Chapter II, pages 
12 and 13, required a large 
number of cores to produce 
the bolt-holes in each side of 
the casting. To meet this 
situation, eight core-boxes 
were mounted on the mould- 
Fig. 126 ing machine shown in Figure 
125, which required an operation of four hours per day to pro- 
duce the rack of cores shown in Figure 126. In the core-room 
in the average foundry producing general castings very little 
attention has been given to the possibilities of producing cores 
on moulding machines ; yet this vast field of possibilities is 
awaiting the foundryman who will follow the lead of those now 
beginning to realize that it is not enough to make the saving 
possible on the moulding floor, but that it should be carried into 
the production of the core-room. 

Figure 127 illustrates at a glance the readiness with which a 
core-box can be mounted on a machine. In fact, the operation 
of mounting a core-box on a moulding machine is a simple one, 
compared to that of mounting the patterns on plates for machine 
work, as with the core-box 
the only requirement is to pro- 
vide the necessary bolts with 
which it is bolted to the ma- 
chine table. The machine 
shown in this view is the 
Roll-Over Jolt type of mould- 
ing machine, which jolt-rams 
the core, rolls it over and 
draws the box from the core by power, leaving it on the drier 
plate. On the run-out car may be seen the core that was pro- 
duced in the box shown mounted on the machine. 




CHAPTER X 

Flask Equipment. 

Of exceptional importance to the successful operation of 
moulding machines is the providing of suitable flasks. It is a 
waste of time and money to attempt the production of good 
moulds on moulding machines without giving the proper con- 
sideration to flask equipment. Every foundryman is familiar 
with the difficulties encountered with the ordinary flask equip- 
ment in use in. the foundries producing moulds by hand-ramming 
methods, and the loss occasioned by the use of flasks that are 
burnt, or have become loosened by the severe handling incident 
to foundry practice. Flasks in this condition should not be used, 
even in hand-moulding, and the time consumed in additional 
care, as well as the loss occasioned by their use, would more 
than offset the loss incurred by scrapping the old flasks and 
making new ones. Those foundries that are accustomed to the 
use of wood flasks only, find it rather difficult to immediately see 
the necessity of changing their viewpoint to coincide with 
modern founding. It had been their practice to roughly nail 
together a set of flasks for most every pattern that was to be 
used, thinking that the cost of wood flasks was small when com- 
pared with iron flasks. No attention was given, nor any attempt 
made, to standardize the flask equipment in order to reduce to 
a minimum the stock of flasks necessary to carry on the foundry 
operations. 

The introduction of moulding machines has made possible 
the standardization of flasks in such a manner as to reduce the 
cost of flask equipment below that of the old style methods, so 
that a better and more durable flask can be made. Such flasks, 
when made of iron and given the proper consideration in han- 
dling, are practically indestructible and, therefore, in the end, are 
the most economical that can be made. 

The subject of flask equipment is vitally important in order 
to bring the foundrymen, inexperienced in foundry moulding- 
machine operation, to a full appreciation and realization of the 



124 Foundry Moulding Machines and Pattern Equipment 

place it occupies in producing moulds by machine methods; and 
therefore, the following views are shown to illustrate the styles 
of flasks that are largely in use for moulding machine production. 

Snap Flasks 

As a large amount of the work produced on air-operated 
squeezer-machines is made in snap-flasks, Figs. 128, 129, 130 and 





Fig. 128 Fig. 129- 

131 are shown to illustrate the different styles in common use 
on those machines. 

The manner in which these flasks are used is clearly set 
forth in the descriptive matter, as well as illustrated in the differ- 
ent photographs of Chapters VII and VIII. 




Fig. 130 Fig. 131 

There is some work of such size and shape as to be readily 
adapted to squeezer-moulding and yet, because of its weight, 
it cannot be successfully made in snap-flasks. Such work is 
usually made in iron flasks of very light construction, as illus- 
trated in Fig. 132. 

The flask shown in Figure 133 illustrates one in common use 
in the aluminum and brass foundry industry. 



Flask Equipment, 



125 



What has been said of the above flasks and their adaptation 
to air-squeezer moulding", can also be said of their use on the 
hand-rammed roll-over type of machine, on such work as does 
not readily lend itself to squeezer-moulding. 




Fig. 132 



Fig. 133 



Cast Iron Flasks and Bottom Plates 

The several preceding chapters have pointed out the im- 
portance of the flask equipment used on the Plain and Roll-Over 
Jolt type of moulding machines, and, therefore, the following 
views are used to show the details of flask construction that are 
recommended for use on the machines that have been described. 

The complete flask illustrated in Figure 134 is used in con- 
nection with the Roll-Over Jolt-Moulding Machine. In this 
view may be seen the type of closing-pin used, which has proved 
to be the best all around type of pin. 

The use of this particular 
type of closing-pin prevents 
the breakage due to the old 
style method of fastening the 
pin in the drag half of the 
mould, while the flasks are be 
ing shaken out and handled in 
the foundry and storage yard. 

It will also be noted in 
Figure 135, which shows the 
cope half of this flask, that the 
bars are secured by means of 
bolts, in order that the flask pig. 134 




126 



Foundry Moulding Machines and Pattern Equipment 



may be used on varying shapes and sizes. To facilitate the 
changing of the bars there are cast in the walls of the flask a 
row of holes which, in addition to their being used for bolts, are 
desirable for "letting off" the gases from the mould. 

Figure 136 shows the drag half of this same flask which, in 
this particular case, requires the use of three special bars con- 





Fig. 135 Fig. 136 

nected as shown. The dove- 
tailed slot shown at either 
end of these flasks makes pos- 
sible the use of cast handle 
bars for handling the empty 
flask when the crane is not 
available. Fig. 137 

Figure 137 shows the type of bottom board that is used with 
this type of flask. The bottom board may be either plain or 
supplied with projections, as here shown. The advantages of 
the projections are many, inasmuch as it is more convenient to 
release the chains when carrying the mould to the foundry floor, 
as well as for attaching the chains after the mould has been 
poured and ready to be taken to the "shake-out" floor; while the 
cost of providing the plates with the projections referred to is 
greater than that of producing the flat plate, nevertheless, when 
it is considered that the plate is to> be used continually, it is well 
to ascertain whether or not the time saved in crane service does 
not far exceed the additional expense of providing the extra 
projections on the plates. 



Flask Equipment. 



127 



On smaller moulds, however, which are of a size that can 
be carried away by hand, without the use of a crane, an inex- 
pensive bottom board is made by the use of cast iron or steel 
plates with standard channel-iron riveted to their back, as is 
shown in Figure 141. 




Fig. 140 

Cut Flasks 

The amount of sand to be handled in a day's production is 
one of importance to the foundryman producing the largest 
quantity of castings, and careful consideration must be given to 
the size and shape of his flask, in order to reduce to a minimum 
the amount of sand to be handled. 

The agricultural and stove plants have developed the "cut- 
flask" in a most remarkable manner, as the years of experience 
in producing agricultural and stove castings by the hand method 
fully demonstrated the lack of wisdom in handling the great 
amount of sand necessary in the rectangular-shaped flask. These 



128 



Foundry Moulding Machines and Pattern Equipment 



plants have also used a mini- 
mum amount of sand between 
the profile of the mould and 
the flask which, of course, is 
made possible only by the fact 
that the flasks which they use 
are of the highest type of de- 
sign and of exceptionally light 
and rigid construction. 

Illustrations of flasks 
shaped to the outline of the 
pattern are shown in Figure 
138, while the flasks shown in 
Figures 139 and 140 are fur- 
ther illustrations of flasks that 
have been made round in 
order to reduce to a minimum 
the amount of sand to be 
handled. 




Fig. 141 



Rolled Steel Flasks 



The descriptions thus far have covered flasks that are to be 
made from castings, either gray iron or aluminum. There has 
been, however, a flask developed which in many respects, on 




Fig. 142 

certain sizes of flasks, is better than those made by casting. This 
particular flask, shown in Figures 142 and 143, is made from 
steel, the section of the flask being designed especially for pro- 
ducing rigidity by means of ribs which are rolled into the plate. 



Flask Equipment 129 



The manufacturers, realizing that there would be a large 
demand for a light and rigid flask, have provided special rolls 
to produce the various shapes required. The shapes are rolled 
in long bars and in the manufacture are shaped by the use of 
a large bending apparatus to the desired size ; the joint is then 
firmly riveted. 

By referring to the illustration of these flasks, it will be 
seen that there are light malleable castings provided for carrying 

the flask pins as well as a light 
section handle casting riveted to 
the corners. 

Mention has been made of 
the importance of the proper 
flask equipment. It is not too 
much to again emphasize the fact 
that without the proper pattern 
and flask equipment, machine- 
moulding is practically an impossibility, and yet it is not desired 
to convey the impression that the providing of the proper patterns 
and flask equipment is a difficult task. The fact of the matter 
is that the proper equipment can be provided with very little, if 
any, additional cost over that for producing the usual equipment 
required for floor moulding. 




CHAPTER XI 

Foundations for Jolt-Ramming 
Moulding Machines 

In order to intelligently consider the proper foundations 
for modern jolt-ramming machines, it is necessary to review 
briefly some of the machines of earlier types. In many instances 
it was considered necessary, to effectively jolt-ram a mold, to 




Fig. 144. Plain Jolt-Ramming Moulding Machine with only Sufficient Foun- 
dation to hold the Machine in place. The Sand may be filled 
around the Machine as the working parts are protected. 



have a machine that would produce a heavy blow. This usually 
was accomplished by building the machine with a stroke of 3 
to 4 or even 6 inches in length. This stroke, of course, would 
produce the heavy blow, its action was not unlike the blow of a 
steam hammer. 

In order to control the ground vibrations produced by such 
a machine, it was necessary to provide massive foundations, and 
in many instances the concrete was capped with several layers 
of wood to aid in the absorption of the blow. 



132 



Foundry Moulding Machines and Pattern Equipment 



The recent rapid development of jolt-ramming machines 
has practically reversed the early theory of design, as it has 
been determined that it is not the force of the machine blow- 
that packs the sand, but that it is packed by the jolting table 
being suddenly or abruptly brought to rest while the sand in 
the flask to be packed continues its downward course, thereby 
producing the pressure which results in the sand packing against 
the pattern or pattern-plate. It is quite evident, therefore, that 




Fig. 145. Foundry Floor View of Jolt-Ramming Power-Stripping Moulding 
Machine with Working Parts Protected. 



if the machine which has been brought suddenly to rest be 
instantly started again on its upward stroke and not allowed to 
pause, an increased pressure of the pattern against the sand 
will result, which causes the sand to lay and not rebound. 

A jolting machine necessary to accomplish this need not 
be unduly massive in its working parts, nor need it have a 
long stroke, 1 to 2 inches usually being sufficient. It should 
have means of controlling the force of the blow of the table 



Foundations for Jolt-Ramming Moulding Machines 



133 



when contacting with the anvil base, as it is evident that 
the weight of the moving table (or dead load) must not be 
allowed to freely drop and contact with the anvil block, or it 
will produce the unnecessary heavy blow. The up-to-date, 
modern jolting machine prevents this heavy blow by providing 




i : 

Fig. 146. Same Machine as Fig, 145, showing Simplicity of Foundation. 



an air cushion under the cylinder sufficient to overcome the 
violent blow caused by the dead load, allowing only sufficient 
blow to accomplish the instant reversal of stroke. 

A machine that accomplishes the foregoing not only will 
ram a good mould in a very short time, but will do so without 
excessive or detrimental vibration in either the machine, pattern 
or foundation. 



134 Foundry Moulding Machines and Pattern Equipment 

As we now approach our subject — the machine foundation 
— it is evident that with such a machine the extremely massive 
foundation is not essential and, therefore, our consideration will 
be from the standpoint of economy and accessibility. 

Of first importance is the kind and nature of the soil upon 
which the machine foundation is to be placed. A dry gravel is 
considered the thing next best to solid rock and will safely stand 
a load of 6,000 to 8,000 pounds per square foot. Dry sand or 



...._^3lS| 




Fig. 147. A Large, 42 x 97-inch, Plain Jolt-Ramming Moulding Machine, 
showing Section through Foundation and Pit. 

dry sand and gravel mixed makes a very good foundation base 
and will withstand a load of 4,000 to 8,000 pounds per square 
foot. Clay soils vary widely ; a soft clay will flow in all directions 
even under very light load, and should not be loaded more than 
3,000 pounds per square foot, while a dry clay will satisfactorily 
stand a load of 3,000 to 5,000 pounds per square foot. If the 
foundation is to be placed on made ground or Ml, provision 
should be made to keep the ground perfectly dry and free from 



Foundations for Jolt-Ramming Moulding Machines 



135 



water. With the proper condition existing a satisfactory founda- 
tion can be made, such condition being more desirable than a wet 
or oozy clay soil. When the foundation is placed on clay or 
fill, better results can be obtained by having it cover a large area 
rather than making it of greater depth, unless the fill is of such 
depth that the foundation may be extended through to solid soil. 




Fig. 148. A 64-inch Roll-Over Jolt-Moulding Machine, showing 
Section through Foundation. 



It must be remembered that when we place a moulding 
machine in the foundry we are actually violating the old estab- 
lished principle of machine installation and placing it in a 
sand pile instead of an engine room, or other dirt and dust- 
proof room, and yet notwithstanding this extraordinary condi- 
tion, and without giving the machine proper care, many found- 
rymen expect as good results from the machine in the sand pile 
as they do from the machine that was placed in a dust-proof 
room and in charge of an expert mechanic. 



136 



Foundry Moulding Machines and Pattern Equipment 




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Foundations for Jolt-Ramming Moulding Machines 137 




Fig. 151. A 36 x 150-inch Roll-Over Jolt-Moulding Machine, Base and 
Foundation shown in Phantom as it appears above foundry floor. 



138 Foundry Moulding Machines and Pattern Equipment 

The accompanying illustrations will demonstrate that it is 
economy to provide a foundation and setting that will give 
ample protection to the machine, by making it impossible for 



*II 



Fig. 152. Foundry Floor View of 42-inch Electrically Operated Roll-Over 
Jolt-Moulding Machine, showing Foundations in Phantom. 



sand to collect on the machine or in its moving parts. They also 
will show the advisability of providing ample space around the 
machine so that the mechanic can easily oil, inspect and keep 
the working parts in order, the same as he does the machine 
placed in the engine room. The depth of the space surrounding 



Foundations for Jolt-Ramming Moulding Machines 139 



1.1 




Fig. 154. This Photograph was taken in the Pit and shows the Excellent 

Condition of the Base of this Jolt-Ramming Moulding Machine 

and its Freedom from Sand, etc. 



140 



foundry Moulding Machines and Pattern Equipment 



the machine should be sufficient for a man to stand erect, suitable 
lighting facilities should be provided and a stairway or ladder 
should lead into the pit. 

The covering of the pit or foundry floor should be made of 
2-inch matched planking and should be fitted tight against the 




Fig. 155 — Entrance Way into the Foundation Pit of a Jolt-Moulding Machine, 
showing Steps leading into the Pit from an Adjoining Basement Room. 



machine. The trap door leading into the pit should be hinged 
and of ample size. 

The engineer or architect called upon to design and build 
the foundry of tomorrow will do well to thoroughly consider 
the best method of installing and maintaining the moulding ma- 
chines to be used, placing them in such manner as to insure 
ample protection from dust and grit and making it easy to give 
the machines the care and attention they deserve. 



Foundations for Jolt-Ramming Moulding Machines 




Fig. 156. View of Jolt-Ramming Moulding Machine, taken in the Pit, show- 
ing Construction of the Pier. 




Fig. 157. View showing Several Jolt-Ramming Moulding Machine Founda- 
tions with Piers built on the Basement Floor. 



142 



Foundry Moulding Machines and Pattern Equipment 













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Foundations for Jolt-Ramming Moulding Machines 



143 



The author's idea of a foundry that will best meet these 
requirements is set forth in Figs. 158 and 159. These illustrations 
show the plan and cross-section of a proposed foundry, having 
a tunnel or basement extending the full length of the moulding 




Fig. 



159. Cross-Section of the Proposed Foundry, showing Tunnel for 
Machine Foundations. 



floor. The floor of this tunnel or basement should be at least 
7 feet below the ceiling and the width should be sufficient to 
allow a clear passageway on one side of the machines; the piers 
for the machine foundations can be placed at any time and to 
suit any condition. 



